Caterpillar C11, C13, C15, C18 Troubleshooting Manual

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Page 1

Troubleshooting

RENR5042-02 February 2005

C11, C13, Engines

JRE1-Up (Engine) WJH1-Up LGK1-Up (Engine) GLS1-Up (Engine)

(Engine)

C15 and C18 Industrial

Page 2

i01658146

Important Safety Information

Most accidents t basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necess

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or dea th.

Do not operate o read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Be

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations th this publication.

hat involve product operation, maintenance and repair are caused by failure to observe

ary training, skills and tools to perform these functions properly.

r perform any lubrication, maintenance or repair on this product, until you have

, bodily injury or death could occur to you or to other persons.

come Alert! Your Safety is Involved.

at may cause product damage are identified by “NOTICE” labels on the product and in

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product w repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was availabl measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any jo

in this publication and on the product are, therefore, not all inclusive. If a tool,

ill not be damaged or be made unsafe by the operation, lubrication, maintenance or

e at the time that the publication was written. The specifications, torques, pressures,

b. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replac specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

ement parts or parts with equivalent

Page 3

RENR5042-02 3

Table of Contents

Troubleshooting Section

Electronic Troubleshooting

System Overview .................................................... 5

Electronic Service Tools .......................................... 6

Electronic Display Module (If Equipped) ................. 8

Replacing the ECM ................................................. 8

Self-Diagnostics ...................................................... 9

Sensors and Electrical Connectors ....................... 10

Engine Wiring Information .................................... 13

Programming Parameters

Programming Parameters ..................................... 15

Customer Passwords ............................................ 15

Factory Passwords ............................................... 15

Factory Passwords Worksheet ............................. 16

Flash Programming .............................................. 16

Injector Trim File ................................................... 17

Service Information Report ................................... 18

System Configuration Parameters

System Configuration Parameters ........................ 20

Troubleshooting without a Diagnostic Code

Alternator (Charging Problem) .............................. 28

Battery .................................................................. 28

Can Not Reach Top Engine RPM ......................... 28

Coolant in Engine Oil ............................................ 30

Coolant Temperature Is Too High ......................... 30

ECM Will Not Accept Factory Passwords ............. 31

ECM Will Not Communicate with Other Systems or

Display Modules .................................................. 31

Electronic Service Tool Will Not Communicate with

ECM .............................................................. ...... 31

Engine Cranks but Will Not Start .......................... 32

Engine Has Early Wear ........................................ 35

Engine Misfires, Runs Rough or Is Unstable ........ 35

Engine Oil in Cooling System ............................... 36

Engine Oil Temperature Is Too High ..................... 37

Engine Stalls at Low RPM .................................... 37

Engine Vibration ................................................... 38

Engine Will Not Crank ........................................... 38

Excessive Black Smoke ........................................ 39

Excessive Engine Oil Consumption ...................... 40

Excessive Fuel Consumption ............................... 41

Excessive Valve Lash ........................................... 42

Excessive White Smoke ....................................... 42

Exhaust Temperature Is Too High ......................... 43

Fuel in Cooling System ......................................... 44

Fuel Dilution of Engine Oil .................................... 44

Intermittent Engine Shutdown ............................... 44

Intermittent Low Power or Power Cutout .............. 45

Low Engine Oil Pressure ...................................... 46

Low Power/Poor or No Response to Throttle ....... 46

Mechanical Noise (Knock) in Engine .................... 48

Noise Coming from Cylinder ................................. 49

Poor Acceleration or Response ............................ 49

Valve Rotator or Spring Lock Is Free .................... 51

Troubleshooting with a Diagnostic Code

Flash Codes .......................................................... 52

Diagnostic Codes .................................................. 52

Diagnostic Code Cross Reference ....................... 53

CID 0001 FMI 05 In

CID 0001 FMI 06 Injector Cylinder 1 short ........... 56

CID 0001 FMI 11 Injector Cylinder #1 fault ........... 57

CID 0002 FMI 05 In

CID 0002 FMI 06 Injector Cylinder 2 short ........... 57

CID 0002 FMI 11 Injector Cylinder #2 fault ........... 58

CID 0003 FMI 05 In

CID 0003 FMI 06 Injector Cylinder 3 short ........... 58

CID 0003 FMI 11 Injector Cylinder #3 fault ........... 59

CID 0004 FMI 05 Inj

CID 0004 FMI 06 Injector Cylinder 4 short ........... 59

CID 0004 FMI 11 Injector Cylinder #4 fault ........... 60

CID 0005 FMI 05 Inje

CID 0005 FMI 06 Injector Cylinder 5 short ........... 60

CID 0005 FMI 11 Injector Cylinder #5 fault ........... 61

CID 0006 FMI 05 Inje

CID 0006 FMI 06 Injector Cylinder 6 short ........... 61

CID 0006 FMI 11 Injector Cylinder #6 fault ........... 61

CID 0041 FMI 03 8 Vol CID 0041 FMI 04 8 Volt DC Supply short to

ground ................................................................. 62

CID 0091 FMI 08 Thro

abnormal ............................................................. 62

CID 0091 FMI 13 Throttle Position calibration

required ............................................................... 63

CID 0094 FMI 03 Fuel Pressure open/short to

+batt .................................................................... 63

CID 0094 FMI 04 Fuel CID 0100 FMI 03 Engine Oil Pressure open/short to

+batt .................................................................... 63

CID 0100 FMI 04 Engin

ground ................................................................. 64

CID 0100 FMI 10 Engine Oil Pressure Sensor

abnormal rate of ch CID 0102 FMI 03 Boost Pressure Sensor short to

+batt .................................................................... 64

CID 0102 FMI 04 Boos

ground ................................................................. 65

CID 0102 FMI 10 Boost Pressure Sensor abnormal

rate of change ..................................................... 65

CID 0110 FMI 03 Engine Coolant Temperature

open/short to +batt .............................................. 65

CID 0110 FMI 04 Engi

to ground ............................................................. 66

CID 0111 FMI 02 Engine Coolant Level Sensor Loss

of Signal .............................................................. 66

CID 0168 FMI 00 System Voltage High ................ 66

CID 0168 FMI 01 System Voltage Low ................. 67

CID 0168 FMI 02 Syst

erratic .................................................................. 67

CID 0172 FMI 03 Intake Manifold Air Temp open/short

to +batt ................................................................ 67

CID 0172 FMI 04 Intake Manifold Air Temp short to

ground ................................................................. 68

CID 0174 FMI 03 Fuel

+batt .................................................................... 68

CID 0174 FMI 04 Fuel Temperature short to

ground ................................................................. 68

CID 0190 FMI 08 Engine Speed abnormal ........... 68

jector Cylinder 1 open circuit .. 56

jector Cylinder 2 open circuit .. 57

jector Cylinder 3 open circuit .. 58

ector Cylinder 4 open circuit .. 59

ctor Cylinder 5 open circuit .. 60

ctor Cylinder 6 open circuit .. 61

t DC Supply short to +batt .. 62

ttle Position signal

Pressure short to ground .. 63

e Oil Pressure short to

ange ..................................... 64

t Pressure Sensor short to

ne Coolant Temperature short

em Voltage intermittent/

Temperature open/short to

Page 4

4 RENR5042-02 Table of Contents

CID 0247 FMI 09 J1939 Data Link

communication CID 0253 FMI 02 Personality Module mismatch .. 69 CID 0261 FMI 13 Engine Timing Calibration

required ............................................................... 69

CID 0262 FMI 03 5 Volt Sensor DC Power Supply

short to +batt ....................................................... 70

CID 0262 FMI 04 5

short to ground .................................................... 70

CID 0268 FMI 02 Check Programmable

Parameters ......................................................... 70

CID 0273 FMI 00 Turbo Outlet Pressure above

normal ................................................................. 71

CID 0274 FMI 03 A

to +batt ................................................................ 71

CID 0274 FMI 04 Atmospheric Pressure short to

ground ................................................................. 71

CID 0342 FMI 08 Secondary Engine Speed signal

abnormal ............................................................. 72

CID 0545 FMI 05 E

+batt .................................................................... 72

CID 0545 FMI 06 Ether Start Relay short to

ground ................................................................. 72

CID 1835 FMI 03 Auxiliary Pressure Sensor

open/short to +batt .............................................. 72

CID 1835 FMI 04

ground ................................................................. 73

CID 1836 FMI 03 Auxiliary Temperature Sensor

open/short to CID 1836 FMI 04 Auxiliary Temperature Sensor short

to ground ............................... .............................. 73

CID 2417 FMI 05

current low .......................................................... 74

CID 2417 FMI 06 Ether Injection Control Solenoid

current high ......................................................... 7

s .................................................. 69

Volt Sensor DC Power Supply

tmospheric Pressure open/short

ther Start Relay open/short to

Auxiliary Pressure Sensor short to

+batt .............................................. 73

Ether Injection Control Solenoid

Electrical Power Supply Circuit - Test ................. 125

Engine Pressur

Test ................................................................... 129

Engine Speed/Timing Sensor Circuit - Test ........ 134

Engine Tempera

Test ................................................................... 140

Ether Injection System - Test .............................. 146

Injector Solen

Maintenance Due Lamp Circuit - Test ................. 160

PTO Switch Circuit - Test .................................... 163

Switch Circuits

Throttle Position Sensor Circuit - Test ................ 171

Warning Lamp Circuit - Test ................................ 176

Calibration Procedures

Engine Speed/Timing Sensor - Calibrate ............ 180

Throttle Positi

e Sensor Open or Short Circuit -

ture Sensor Open or Short Circuit -

oid Circuit - Test ............................ 152

- Test .......................................... 168

on Sensor - Calibrate .................... 182

Index Section

Index ................................................................... 185

Troubleshooting with an Event Code

Event Codes ........................................................ 75

E057 Low Engine Coolant Level Derate ............... 79

E058 Low Engine Coolant Level Shutdown .......... 79

E059 Low Engin

E096 High Fuel Pressure ...................................... 81

E360 Low Engine Oil Pressure ............................. 81

E361 High Engin

E362 Engine Overspeed ....................................... 83

E363 High Fuel Temperature ................................ 83

E443 High Auxili

E445 High Auxiliary Temperature ......................... 84

E539 High Intake Manifold Air Temperature ......... 85

Diagnostic Functional Tests

5 Volt Engine Pressure Sensor Supply Circuit -

Test ..................................................................... 87

Air Shutoff System - Test ...................................... 95

CAN Data Link Circuit - Test ............................... 100

Cat Data Link Cir

Coolant Level Sensor Circuit - Test .................... 106

Diagnostic Lamp Circuit - Test ............................. 110

Digital Sensor Su

ECM/Personality Module - Test ........................... 118

Electrical Connectors - Inspect ........................... 120

e Coolant Level Warning ............ 80

e Coolant Temperature .............. 82

ary Pressure ............................... 84

cuit - Test ................................. 104

pply Circuit - Test ..................... 114

Page 5

RENR5042-02 5

Troubleshooting Section

Electronic Troubleshooting

i02286178

System Overview

SMCS Code: 19

System Opera

This engine is electronically controlled. Each cylinder has an electr Module (ECM) sends a signal to each injector solenoid in order to control the operation of the fuel injection sy

Electronic Controls

The electronic system consists of the following components: the ECM, the Mechanically Actuated Electronic wiring harness, the switches, and the sensors. The ECM is the computer. The flash file is the software for the com maps. The operating maps define the following characteristics of the engine:

Horsepower

•

Torque cur

•

TheECMdeterminesthetimingandtheamountof fuel that are based on the actual conditions and/or on the desired conditions at any given time.

The ECM compares the desired engine speed to the actual engine speed. The actual engine speed is determin The desired engine speed is determined with the following factors:

Throttle signal

•

Other in

•

Certain diagnostic codes

•

If the desired engine speed is greater than the actual engine speed, the ECM injects more fuel in order to increas

ally Controlled Unit Injectors (MEUI), the

is delivered to the cylinders. These decisions

ed through the engine speed/timing sensor.

e the actual engine speed.

tion

onic unit injector. The Electronic Control

stem.

puter. The flash file contains the operating

ves

put signals from sensors

Fuel Injection

The ECM controls the amount of fuel that is injected by varying the signals to the injectors. The injector will pump fuel only The ECM sends a high voltage signal to the solenoid. This high voltage signal energizes the solenoid. By controlling voltage signal, the ECM can control injection timing and the ECM can control the amount of fuel that is injected.

The ECM limits engine power during cold mode operation an during cold mode operation. Cold mode operation provides the following benefits:

Increased cold weather starting capability

•

Reduced war

•

Reduced white smoke

•

Cold mode is activated whenever the engine temperature falls below a predetermined value. Cold mode remain rises above a predetermined value or until a time limit is exceeded.

The flash file inside the ECM sets certain limits on theamountoffuelthatcanbeinjected.The“FRC Fuel Limit control of emissions. The “FRC Fuel Limit” is a limit that is based on the turbocharger outlet pressure. A higher tu thereismoreairinthecylinder.WhentheECM senses a higher turbocharger outlet pressure, the ECM incre increases the “FRC Fuel Limit”, the ECM allows more fuel into the cylinder. The “FRC Fuel Limit” is program Fuel Limit” cannot be changed.

The “Rat power rating of the engine and on engine rpm. The “Rated Fuel Limit” is similar to the rack stops and to the torq The “Rated Fuel Limit” provides the power curves and the torque curves for a specific engine family and for a sp programmed into the ECM at the factory. The “Rated Fuel Limit” cannot be changed.

Once the ECM determines the amount of fuel that is required, the ECM must determine the timing of the center position of each cylinder from the engine speed/timing sensor’s signal. The ECM decides when fuel i position and the ECM provides the signal to the injector at the desired time. The ECM adjusts timing for o economy, and for optimum control of white smoke.

medintotheECMatthefactory.The“FRC

ue spring on a mechanically governed engine.

ecific engine rating. The “Rated Fuel Limit” is

fuel injection. The ECM calculates the top

njection should occur relative to the top center

ptimum engine performance, for optimum fuel

if the injector solenoid is energized.

the timing and the duration of the high

d the ECM modifies injection timing

m-up time

s active until the engine temperature

”isusedtocontroltheair/fuelratiofor

rbocharger outlet pressure indicates that

ases the “FRC Fuel Limit”. When the ECM

ed Fuel Limit” is a limit that is based on the

Page 6

6 RENR5042-02 Troubleshooting Section

Programmable P

arameters

Certain parameters that affect the engine operation may be changed w

ith Caterpillar Electronic Technician (ET). The parameters are stored in the ECM, and some parameters are protected from unauthor

ized changes by passwords. These

passwords are called factory passwords.

Passwords

Several syst logged events are protected by factory passwords. Factory passwords are available only to Caterpillar dealers. Ref Passwords” for additional information.

em configuration parameters and most

er to Troubleshooting, “Factory

i02290247

Electronic Service Tools

SMCS Code: 0

Caterpillar Electronic Service Tools are designed to help the ser

Obtain data.

•

785

vice technician:

Table 1

Required Service Tools

Part

Number

N/A

6V-2197

7X-1171 Transducer Adapter

7X-1695

146-4080

7X-1710 Multimeter Probes

208-0059

7X-6370

167-9225

1U-5804

175-3700

4 mm Allen Wrench

Transducer

Cable As

Digital Multimeter Gp (RS232)

Adapter Cable As (70-PIN BREAKOUT)

Adapter Cable As (3-PIN BREAKOUT)

Harness (SERVICE TOOL ADAPTER)

Crimp Tool (12−AWG TO 18−AWG)

ConnectorRepairKit(DEUTSCHDT)

Description

Two short jumper wires are needed to check the continuity of some wiring harness circuits by shorting two adjacent terminals together in a connector. A long extension wire may also be needed to check the continuity of some wiring harness circuits.

Diagnose problems.

•

Read parame

•

Program parameters.

•

Calibrate sensors.

•

ters.

Required Service Tools

The tools th order to enable a service technician to perform the procedures.

at are listed in Table 1 are required in

Optional Service Tools

Table 2 lists the optional service tools that may help you service the engine.

Table 2

Optional Service Tools

Part Number Description

198-4240

1U-5470

4C-4075

4C-4911

5P-7277

6V-9130

8T-5319

155-5176

(1)

Refer to Special Instructions, SEHS9249, “Use of 4C-4911 Battery Load Tester for 6, 8, and 12 Volt Lead Acid Batteries” and Special Instructions, SEHS7633, “Battery Test Procedure”.

(2)

Refer to Special Instructions, SEHS 8382, “Use of the 6V-9130 Tem perature Adapter Group”.

Digital Pressure Indicator

Engine Pressure Group

Crimp Tool (4−AWG TO 10−AWG)

(1)

Battery Load Tester

Voltag e Teste r

(2)

Temperature Adapter (MULTIMETER)

Connector Tool Group

AC/DC Current Probe

Caterpillar Electronic Technician (ET)

Cat ET can display the following information:

Page 7

RENR5042-02 7

Troubleshooting Section

Parameters

•

Event codes

•

Diagnostic cod

•

Engine configuration

•

Cat ET can be used by the technician to perform the following functions:

Diagnostic tests

•

Sensor calibr

•

Flash programming

•

Set parameters

•

Table3listst

ation

he service tools that are required in

order to use Cat ET.

Table 3

Service Tools for the Use of Cat ET

Part

Number

Description

Connecting Cat ET and the Communication

Adapter II

N/A Personal Computer (PC)

JERD2124

JERD2129

171-4400

237-7547

(1)

The 7X-1700 Communication Adapter Gp may also be used.

(2)

The 237-7547 Adapter C able As is required to connect to the USB port on computers that are not equipped with a RS232 serial port.

Single user license for Cat ET

Data Subscription for All Engines and Machines

Communication Adapter Gp (CAT ET TO

(1)

ECM INTERFACE) ()

(2)

Adapter Cable As

Note: For more information regarding the use of Cat ET and the PC requirements for Cat ET, refer to the documentation that accompanies your Cat ET software.

Illustration 1

(1) Personal compu ter (PC) (2) 196-0055 Adapter Cable As (3) 1 71-4401 Comm unication Adapter As (4) 207-6845 Adapter Cable As

g01115382

Note: Items (2), (3), and (4) are part of the 171-4400 Communication Adapter Gp.

Use the following procedure in order to connect Cat ET and the Communication Adapter II.

1. Turn the keyswitch to the OFF position. If the keyswitch is not in the OFF position, the engine may start.

2. Connect cable (2) between the “COMPUTER” end of communication adapter (3) and the RS232 serial port of PC (1).

Note: The 237-7547 Adapter Cable As is required to connect to the USB port on computers that are not equipped with a RS232 serial port.

3. Connect cable (4) between the “DATA LINK” end of communication adapter (3) and the service tool connector.

Page 8

8 RENR5042-02 Troubleshooting Section

4. PlacethekeyswitchintheONposition.If Cat ET and the co not communicate with the Electronic Control Module (ECM), refer to the diagnostic procedure Troubleshoot Communicate With ECM”.

mmunication adapter do

ing, “Electronic Service Tool Will Not

i02139021

Electronic D isplay Module (If Equipped)

SMCS Code: 7490

An electronic display CID-FMI information from the electronic control system. Refer to the service manual for your electronic d

display module may be used to

isplay module for more information.

i02290070

Replacing the ECM

SMCS Code: 1901-510

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE Keep all pa

Contaminants may cause rapid wear and shortened component

rts clean from contaminants.

life.

Note: Ensure that the ECM is receiving power and that the ECM is p circuit before a replacement of the ECM is attempted. Refer to Troubleshooting, “Electrical Power Supply Circuit - Test

AtestECMcanbeusedtodetermineiftheECMis faulty. Inst Flash program the correct flash file into the test ECM. Program the parameters for normal operation of the engine. The p in the suspect ECM. Refer to the following test steps for details. If the test ECM resolves the problem, connect the returns. If the problem returns, replace the suspect ECM.

Note: When a new ECM is not available, you may need to remove an ECM from an engine that is not in service. ECM must match the interlock code for the suspect ECM. Be sure to record the parameters from the replaceme Use the “Copy Configuration/ECM Replacement” feature that is found under the “Service” menu on the Caterpil

If the flash file and engine application are not matched, engine da

Perform the following procedure in order to replace the ECM:

1. Record the configuration data:

a. Connect Cat ET to the service tool connector.

b. Print the parameters from the “Configuration”

all a test ECM in place of the suspect ECM.

lar Electronic Technician (ET).

mage may result.

Refer to Troubleshooting, “Electronic Service Too ls ”.

screen on record all of the parameters. Record any logged diagnostic codes and logged event codes fo codes from the “Calibrations” screen in the “Service” menu on Cat ET.

roperly wired to the negative battery

”.

arameters must match the parameters

suspect ECM. Verify that the problem

The interlock code for the replacement

nt ECM on the “Parameters Worksheet”.

NOTICE

Cat ET. If a printer is unavailable,

r your records. Record the injector

The Electronic Control Module (ECM) contains no moving parts. Replacement of the ECM can be costly. Replacement can also be a time consuming task. Follow the troubleshooting procedures in this manual in order to ensure that replacing the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem.

c. Use the “Copy Configuration/ECM

Replacement” feature that is found under the

ce” menu on Cat ET. Select “Load from

“Servi ECM” in order to copy the configuration data from the suspect ECM.

Note: If the “Copy Configuration” process fails and the parameters were not obtained in Step 1.b, the parame parameters are stamped on the engine information plate. Most of the parameters must be obtained from the fa

ters must be obtained elsewhere. Some of the

ctory.

Page 9

RENR5042-02 9

Troubleshooting Section

2. Remove the ECM:

a. Turn the keyswitch to the OFF position.

b. Disconnect the

the ECM.

Use a suitable container to catch any fuel that might spill. Clean u

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

c. Remove the fuel lines (if equipped) from the

ECM.

d. Disconnect the ECM ground strap.

e. Remove the mounting bolts from the ECM.

3. Install the replacement ECM:

p any spilled fuel immediately.

P1 and P2 connectors from

NOTICE

c. If the “Copy Configuration” process from

Step 1.b was suc Configuration/ECM Replacement” screen on Cat ET and select “Program ECM”. Proceed to Step 4.e when p

d. If the “Copy Configuration” process from Step

1.b was unsuc ECM parameters. The parameters must match the parameters from Step 1.b.

e. Program the engine monitoring system, if

necessary.

f. Load the injector trim files for the injectors.

Refer to Troubleshooting, “Injector Trim File”.

g. Calibrate the engine speed/timing. Refer

to Troubleshooting, “Engine Speed/Timing Sensor - Cal

Self-Diagn

SMCS Code: 1901

cessful, return to the “Copy

rogramming is complete.

cessful, manually program the

ibrate”.

ostics

i02101273

a. Use the old mounting hardware to install the

replacement ECM.

b. Connect the fuel lines (if equipped).

Note: Verify that the fuel lines are installed correctly.

The fuel lines must not put tension on the ECM. Rubber grommets are used to protect the ECM from excessive vibration. The ECM should move slightly in the rubber grommets. If the ECM cannot be moved slightly, check that the fuel lines are not pulling the ECM against one side of the grommets.

c. Connect the ECM ground strap.

d. Connect the P1 and P2 connectors. Tighten

the ECM connector (allen head screw) to the proper torque. Refer to Troubleshooting, “Electrical Connectors - Inspect” for the correct torque value.

4. Configure the replacement ECM:

a. Flash program the flash file into the ECM.

Refer to Troubleshooting, “Flash Programming” for the correct procedure.

b. Use Cat ET to match the engine application

and the interlock code if the replacement ECM was used for a different application.

The Electronic Control Module (ECM) has the ability to detect problems with the electronic system and with engine code is generated. An alarm may also be generated. There are two types of codes:

Diagnostic

•

Event

•

Diagnostic Code – When a problem with the electroni diagnostic code. This indicates the specific problem with the circuitry.

Diagnostic codes can have two different states:

Active

•

Logged

•

Active Code – An active diagnostic code indicates that an active problem has been detected. Active codes req active codes prior to servicing logged codes.

Logged Co

the permanent memory of the ECM. The codes are logged.

Event Code – An event code is generated by the detection of an abnormal engine operating condition. For exam oil pressure is too low. In this case, the event code indicates the symptom of a problem.

operation. When a problem is detected, a

c system is detected, the ECM generates a

uire immediate attention. Always service

de – Every generated code is stored in

ple, an event code will be generated if the

Page 10

10 RENR5042-02 Troubleshooting Section

Logged codes may not indicate that a repair is needed. The pro

blem may have been temporary. The problem may have been resolved since the logging of the code. If the system is powered, it is possible to generate an

active diagnostic code whenever a component is disconnected. When the component is reconnected, the code is no longer active. Logged codes may be u

seful to help troubleshoot intermittent problems. Logged codes can also be used to review the performance of the engine and of the electronic system.

Sensors and Electrical Connectors

SMCS Code: 1900-NS; 7553-WW

Table 4

Connector

J1/P1 ECM Connector

J2/P2 ECM Connector (“120-Pin Engine

J61/P61 Customer Connector (Optional)

J63/P63 Service Tool Connector (9-Pin

J66/P66 Customer Su

J100/P100 Coolant Temperature Sensor (2-Pin

J103/P103 Intake Manifold Air Temperature

J105/P105 Fuel Temperature Sensor (2-Pin

J142/P14

J200/P200 Boost Pressure Sensor (3-Pin

J201/P201 Engine Oil Pressure Sensor (3-Pin

J203/P203 Atmospheric Pressure Sensor (3-Pin

J209/P209 Fuel Pressure Sensor

J220/P220 Auxiliary Pressure Sensor

J300/P300 Injector Solenoid Harness (12-Pin

J400/P400 Engine Timing Calibration Probe

/P401

J401

J402/P402 Secondary Engine Speed/Timing

J403/P403 Throttle Position Sensor (3-Pin

J800/P800 Engine Coolant Level Sensor

Harness)

Harness”)

(40-Pin Connector)

Connector)

Connector (9-Pin Connector)

Connector)

Sensor (2-Pin Connector)

Connector)

Auxiliar

Connector)

(2-Pin Connector)

ary Engine Speed/Timing

Prim Sensor (Crankshaft) (2-Pin Connector)

Sensor (Camshaft) (2-Pin Connector)

Connector)

Function

(70-Pin Engine

pplied Service Tool

y Temperature Sensor

i02077683

Page 11

RENR5042-02 11

Troubleshooting Section

stration 2

Illu

Components for the engine’s c ontrol system

g01104142

Page 12

12 RENR5042-02 Troubleshooting Section

C11andC13Engines

Illustration 3

Location

(1) Coolant temperature sensor (2) Atmospheric pressure sensor (3) Secondary engine speed/timing sensor

s of the sensors on C11 and C13 engines

(4) Fuel pressure sensor (5) Engine oil pressure s ensor (6) Boost pressure sensor

g01099946

(7) Fuel temperature sensor (8) Intake m anifold air temperature sensor (9) Primary engine speed/timing sensor

Page 13

RENR5042-02 13

Troubleshooting Section

C15 and C18 Engines

Illustration 4

Location

(1) Coolant temperature sensor (2) Secondary engine speed/timing sensor (3) Boost pressure sensor

s of the sensors on C 15 and C1 8 engines

(4) Fuel pressure sensor (5) Fuel temperature sensor (6) Intake m anifold air temperature sensor

i0228538

Engine Wiring Information

SMCS Code: 1408

The wirin The wiring schematics will change as updates are made to the machine harness. For the most current informa schematic. Use the schematic with the latest revision number.

Harness Wire Identification

Caterpillar identifies all wires with eleven solid colors. The circuit number is stamped on the wire at a 25 mm (1 inch color codes.

g schematics are revised periodically.

tion, always check the revision number of the

) spacing. Table 5 lists the wire colors and the

g01099949

(7) Engine oil pressure sensor (8) Atmospheric pressure sensor (9) Primary engine speed/timing sensor

Table 5

Color Codes for the Harness Wire

Color Code Color Color Code Color

BK Black

BR Brown BU Blue

RD Red PU Purple

OR Orange GY Gray

YL Yell o w WH White

GN Green

PK Pink

For example, a wire identification of A701-GY on the schematic would signify a gray wire with the circuit number A701. A701-GY identifies the power circuit for the No. 1 Injector solenoid.

Another wire identification on the schematic is the size of the wire. The size of the wire will follow the wire color. Wire size or gauge is referred to as AWG (Americal Wire Gauge). AWG is a description of the diameter of the wire.

Page 14

14 RENR5042-02 Troubleshooting Section

For example, a code of 150-OR-14 on the schematic would indicate

thattheorangewireincircuit150isa

14 AWG wire.

If the gauge of

the wire is not listed, the wire is 16

AWG.

Conversion of

AWG Numbers to Metric

Measurements

Table6showst used for the wires. The metric equivalent for the diameter of each AWG number are also shown.

Table 6

Metric Equivalents for AWG Numbers

AWG

Number

20 0.8 14 1.6

18 1.0 12 2.0

16 1.3 4 3.2

he various AWG numbers that are

Diameter

(mm)

AWG

Number

Diameter

(mm)

Welding on a Machine that is Equipped

ith an Electronic Control System (ECM)

Proper welding procedures are necessary in order

o avoid damage to the engine’s electronic control

t module, sensors, and associated components. The component that requires welding should be removed. When welding on a machine that is equipped with an ECM and removal of the component is not possible, the following procedure must be followed. This procedure provides the minimum amount of risk to the electronic components.

Illustration 5

Service welding guide (typical diagram)

g01143634

3. Connect the welding ground cable as close as possible to the area that will be welded. Components which may be damaged by welding include bearings, hydraulic components, and electrical/electronic components.

4. Protect the wiring harness from welding debris and from spatter.

5. Weld the materials by using standard welding methods.

NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components.

Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage.

1. Stop the engine. Turn the keyswitch to the OFF

position.

2. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is installed, open the switch.

Page 15

RENR5042-02 15

Troubleshooting Section

Programming Pa

rameters

i02253984

Programming Parameters

SMCS Code: 1901

The Caterpillar Electronic Technician (ET) can be used to view certain parameters that can affect the operation of the engine. Cat ET can also be used to change certain parameters. The parameters are stored in the Electronic Control Module (ECM). Some of the parameters are protected from unauthorized changes by passwords. Parameters that can be changed have a tattletale number. The tattletale number shows if a parameter has been changed.

i02213792

Customer Pass words

SMCS Code: 0785

Customer pa

Alphanumeric

•

Eight characters in length

•

“Customer P

•

“Customer Password #1” can be programmed and

•

“Customer Password #2” can be programmed.

sswords must meet the following criteria:

assword #1” can be programmed.

Use the following procedure in order to read customer passwords with

1. Access the “Utilities menu”. Then access “View Passwords” un

2. When the “Factory Password” screen appears, record the inf Passwords Worksheet”. Refer to Troubleshooting, “Factory Passwords Worksheet” for additional information

3. Obtain the factory passwords. The information that is recor Worksheet” must be provided. When you obtain the factory passwords, a permanent record of your access is gen

4. From the “Factory Password” screen, enter the factory pas

5. When the “Read Customer Passwords” screen appears, re customer passwords may then be used to change parameters that are customer programmable.

Cat ET:

der the “Utilities menu”.

ormation that is listed on the “Factory

ded on the “Factory Passwords

erated at Caterpillar.

swords.

cord the customer passwords. The

i02274501

Factory Passwords

SMCS Code: 0785

NOTICE Operating the engine with a flash file not designed for that engine will damage the engine. Be sure the flash file is correct for your engine.

No custome

•

If customer passwords have been entered, then the custom any parameter that is customer programmable. Parameters that are customer programmable are those para limits, the power rating within an engine family and the PTO operation. Refer to Troubleshooting, “System C on parameters that are customer programmable.

Use the Ca change parameters that are customer programmable. To obtain customer passwords, contact the owner of the en passwords, customer passwords may be read by using Cat ET.

Note: Factory passwords are required in order to read customer passwords.

r passwords are programmed.

er passwords are required to change

meters that affect the engine speed

onfiguration Parameters” for more detail

terpillar Electronic Technician (ET) to

gine. If the owner has lost the owner’s

Note: Factory passwords are provided only to Caterpillar dealers.

Factory passwords are required to perform each of the following functions:

Program a new Electronic Control Module (ECM).

•

When an ECM is replaced, the system configuration parameters must be programmed into the new ECM. A new ECM will allow these parameters to be programmed once without factory passwords. After the initial programming, some parameters are protected by factory passwords.

Clear event codes.

•

Most event codes require the use of factory passwords to clear the code once the code has been logged. Clear these codes only when you are certain that the problem has been corrected.

Page 16

16 RENR5042-02 Troubleshooting Section

Unlock parameters.

•

Factory passwords are required in order to unlock certain system configuration parameters. Refer to Troublesho

oting, “System Configuration

Parameters” for additional information.

Since factor

y passwords contain alphabetic characters, the Caterpillar Electronic Technician (ET) must be used to perform these functions. In order to obtain facto

ry passwords, proceed as if you already have the password. If factory passwords are needed, Cat ET will request the factory passwords and Cat ET will d

isplay the information that is required to obtain the passwords. For the worksheet that is used for acquiring factory passwords, refer to Troublesho

oting, “Factory Passwords Worksheet”.

i02170328

Factory Passwords Worksheet

SMCS Code: 0785

Note: A mistake in recording these parameters will

result in incorrect passwords.

Table 7

Factory Passwords Worksheet

Dealer Code

Customer’s Name

Address

Telephone Number

Information From the Engine Information Plate

Engine Serial Number

Full Load Setting

Full Torque Setting

Information From the Vehicle Odometer

Engine’s M

Information From the “Factory Password Entry

Screen” on the Caterpillar Electronic Technician (ET)

Electronic Service Tool Serial Number

Engine Serial Number

ECM Serial Number

Total Tattletale

Reason Code

From Interlock

To I n te rl oc k

Factory Password (No. 1)

Factory Password (No. 2)

(1)

This parameter is required when the engine is being rerated. This parameter is displayed only when the engine is being rerated.

iles (km)

(1)

Factory Passwords

i02253997

Flash P rog ramming

SMCS Code: 1901-591

Flash Programming – This is a method of

programming or updating the flash file in an Electronic Control Module (ECM).

The Caterpillar Electronic Technician (ET) can be utilized to flash a new flash file into the ECM. The flash is accomplished by transferring the data from a PC to the ECM.

Page 17

RENR5042-02 17

Troubleshooting Section

Programming a F

1. Obtain the part number for the new flash file.

Note: If you do not have the flash file’s part number,

use the “Flash File Search” tool on the Service Technician Wor “Flash Software Files” feature on SIS Web.

Note: You mu s t order to search for the flash file’s part number.

2. Connect Cat ET

3. Turn the keyswitch to the ON position. Do not start

the engine.

4. Select “WinFlash” from the “Utilities” menu on Cat

ET.

Note: If “WinFlash” will not communicate with the ECM, refer to Tool Will Not Communicate with ECM”.

5. Program the f

a. Select the engine ECM under the “Detected

ECMs”.

b. Press the “Browse” button in order to select

the part num programmed into the ECM.

c. When the cor

the “Open” button.

d. Verify that

application. If the “File Values” do not match the application, search for the correct flash file.

e. When the correct flash file is selected, press

the “Begin Flash” button.

kbench (STW). Alternatively, use the

have the engine serial number in

Troubleshooting, “Electronic Service

lash file into the ECM.

ber of the flash file that will be

the “File Values” match the

lash File

to the service tool connector.

rect flash file is selected, press

“WinFlash” Error Messages

If you receive any error messages during flash programming, click on the “Cancel” button in order to stop the pro the “ECM Summary” under the “Information” menu. Make sure that you are flashing the correct file for your engine.

cess. Access the information about

i02289388

Injector Trim File

SMCS Code: 1290

The Caterpillar Electronic Technician (ET) is used to load the injector trim files into the Electronic Control Module (ECM).

The injector trim files must be loaded into the ECM if any of the following conditions occur:

An injector is replaced.

•

The ECM is replaced.

•

A 268-02 diagnostic code is active.

•

Injectors are exchanged between cylinders.

•

Exchanging Injectors

Exchanging injectors can help determine if a combustion problem is in the injector or in the cylinder. If two injectors that are currently installed in the engine are exchanged between cylinders, the injector trim files can also be exchanged. Press the “Exchange” button at the bottom of the “Injector Trim Calibration” screen on Cat ET. Select the two injectors that will be exchanged and press the “OK” button. The tattletale for the injectors that were exchanged will increase by one.

f. Cat ET will indicate when flash programming

has been successfully completed.

6. Start the engine and check for proper operation.

a. If a diagno

Programmable Parameters is generated, program any parameters that were not in the old flash

b. Access the “Configuration” screen under

the “Serv the parameters that require programming. Look under the “Tattletale” column. All of the paramete more. If a parameter has a tattletale of 0, program that parameter.

stic code of 268-02 Check

file.

ice” menu in order to determine

rs should have a tattletale of 1 or

Note: The injector serial number and the injector confirmation code are located on the injector.

1. Refer to Table 8. Record the injector serial number and the injector confirmation code for each injector.

Page 18

18 RENR5042-02 Troubleshooting Section

Table 8

Information for the Injectors

Cylinder Serial Number Confirmation

2. Click on “Injector Trim Files” in SIS Web.

3. Enter the serial number for the injector in the

search field.

4. Download the injector trim file to the PC. Repeat this procedure for each injector, as required.

5. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Too ls ”.

6. Turn the keyswitch to the ON position.

7. Select the following menu options on Cat ET:

Service

•

Calibrations

•

Injector Trim Calibration

•

Code

12. Enter the confirmation code if required by Cat ET.

13. Click on the “OK” button.

The injector tr

14. Repeat the procedure for each cylinder, as required.

im file is loaded into the ECM.

i02278907

Service Information Report

SMCS Code: 0336

After verifyi on the engine, it is critical to provide brief, detailed information. This information helps Caterpillar better serve you and

Recommendat

Customer’s Complaint

Obtain as much information from the customer as possible. Investigate any written information that is avai that is gathered from the customer. The following information is of particular importance:

Indicate if the diagnostic lamp was flashing.

•

Indicate if

•

lamp was on continuously.

Indicate t

•

present.

Be as speci

Cause of Failure

Comments on the cause of failure should include the number of diagnostic codes that were logged. Comments s active code. Indicate the source of the problem. Also indicate the method that was used to discover the problem. E discover the problem could be one of the following methods:

ng the correct repair has been performed

the customer.

ions

lable and document any information

the warning lamp was flashing, or if the

he symptoms of engine operation that are

fic as possible.

hould also indicate if the code was an

xamples of the methods that were used to

8. Select the appropriate cylinder.

9. Click on the “Change” button.

10. Select the appropriate injector trim file from the

PC.

11. Click on the “Open” button.

A specific procedure in the manual was followed.

•

Avisuali

•

the engine harness existed.

nspection indicated that wire abrasion on

Page 19

RENR5042-02 19

Troubleshooting Section

An engine dynamometer test indicated that the

•

power was below due to the loss of the no. 4 injector and an engine dynamometer test indicated that the power was below the spec 1700 rpm due to the loss of the no. 4 injector.

the specification at 1700 rpm

ification at all engine speeds above

Be as specifi

caspossible.

Repair Procedure

Comments on the repair procedure should include the following types of information:

The wiring harness was repaired.

•

The Full Load

•

factory’s instructions.

Be as specifi

Setting (FLS) was changed per the

caspossible.

Page 20

20 RENR5042-02 Troubleshooting Section

System Configuration Parameters

i02290263

System Configuration Parameters

SMCS Code: 1901

System configuration parameters are parameters that affect the emissions and the power of the engine. Default values for the parameters are programmed at the factory. Some parameters may be changed by the customer in order to suit the needs of the specific application.

Parameter Descriptions

“Equipment ID”

“Equipment ID” allows the customer to enter a description into the Electronic Control Module (ECM) in order to identify the machine. A maximum of 17 characters may be entered in the field. This parameter is only for reference by the customer. This parameter is not required.

“Top Engine Limit” (TEL)

Illustration 6

“TEL” is a customer programmable parameter that defines the maximum allowable engine speed for maximum power. “TEL” can be programmed up to the maximum rated engine speed. “TEL” is defined along the engine’s lug curve.

g00763900

“Engine Serial Number”

Program the “Engine Serial Number” to match the engine serial number that is stamped on the engine information plate. If the ECM is replaced, the engine serial number from the engine information plate must be programmed into the new ECM.

Note: When you are requesting factory passwords, always use the engine serial number that is programmed in the ECM.

“Rating Number”

The “Rating Number” corresponds to the selected set of performance maps for the application. This selected set of performance maps comes out of several unique sets of maps that are resident in the flash file. The dealer and/or the OEM will need to select the appropriate rating tier, if more than one rating tier is present. The rating tiers are A through E.

Note: Factory passwords are required in order to change the “Rating Number”.

“Engine Accel. Rate”

“Engine Accel. Rate” determines the rate of change of the engine speed (acceleration or deceleration) during PTO operation. This rate of change is also used to achieve intermediate engine speed.

“Low Idle Speed”

“Low Idle Speed” is the minimum allowable operating speed for the engine. This parameter can be programmed between 600 and 1400 rpm.

“PTO Mode”

“PTO Mode” allows the ECM to be programmed to either one of the two PTO configurations that are available.

“Ramp Up/Ramp Down” – When “PTO Mode” is programmed to “Ramp Up/Ramp Down”, the ECM allows PTO operation with traditional features.

“Set/Resume” – When “PTO Mode” is programmed to “Set/Resume”, the ECM allows PTO operation with enhanced features.

Page 21

RENR5042-02 21

Troubleshooting Section

“High Idle S peed”

Illustration 7

“High Idle Speed” is the maximum no-load engine speed when the throttle or the PTO switch is in the maximum position.

g00763900

“Maximum Engine Torque Limit”

Illustration 8

“Engine Torque Limit” can be used to limit torque output to the programmed value when the torque limit switch is activated.

g00817759

Note: “High Idle Speed” cannot be programmed lower than “TEL”.

“Intermediate Engine Speed”

“Intermediate Engine Speed” defines the speed for the engine when the intermediate engine speed switch is activated. This parameter can be programmed to any engine speed between “Low Idle Speed” and “TEL”. Engine speed will increase or engine speed will decrease at the rate that is defined by the programmed value for “Engine Accel. Rate”.

“Engine Power Trim”

This parameter cannot be changed.

“FLS” (Full Load Setting)

“FLS” is a number that represents the adjustment to the fuel system that was made at the factory in order to fine tune the fuel system. The correct value for this parameter is stamped on the engine information plate. Factory passwords are required in order to change this parameter.

“FTS” (Full Torque Setting)

“FTS” is similar to “FLS”. Factory passwords are required in order to change this parameter.

“Ether Control”

Program the “Ether Control” to “Enabled” if an ether injection system is installed on the engine. This allows the ECM to control ether injection. If the engine is not equipped with ether, program this parameter to “Disabled”.

“Air Shutoff ”

“Air Shutoff” allows the ECM to be programmed for operation of an air shutoff system. If this parameter is programmed to “Installed”, the ECM will activate the air shutoff solenoid in the event of an engine overspeed condition.

Page 22

22 RENR5042-02 Troubleshooting Section

Note: If an engine overspeed condition occurs and “Air Shutof switched power to the ECM must be cycled and the air shutoff solenoid must be manually reset before the engine wil

f” is programmed to “Enabled”, the

lrestart.

“Maintenance Indicator M ode”

The ECM records data that is related to equipment maintenance. The ECM will activate the maintenance indicator la due. The maintenance indicator lamp can be reset by actuating the maintenance clear switch. The maintenance hours or on fuel consumption. The ECM provides information that pertains to maintenance intervals and the last

mp when scheduled maintenance is

interval may be based on operating

maintenance that was performed.

“PM1 Interval”

“PM1 Interval” allows the customer to define the maintenance interval if “Maintenance Indicator Mode” is program to the engine’s Operation and Maintenance Manual for more information.

med to one of the manual options. Refer

“Aux Temp Sensor Installation Status”

Program “Aux Temp Enable” to “Installed” if an auxiliary temperature sensor is installed. This will allow the disp (EMS) to monitor the temperature of another system. Program this parameter to “Not Installed” if an auxiliary te

lay for the Engine Monitoring System

mperature sensor is not installed.

“Throttle Position Sensor”

Program th if a throttle position sensor is used for desired speed control. Otherwise program this parameter to “Not Installed

e “Throttle Position Sensor” to “Installed”

”.

“Coolant Level Sensor”

Program the “Coolant Level Sensor” to “Installed” if a coolant level sensor is installed on the engine. Otherwis

e program this parameter to “Not Installed”.

“Direct Fuel Control Mode”

Program the “Direct Fuel Control Mode” to “Enabled” if an external governor is used. Once this parameter is enable disabled. Otherwise program this parameter to “Disabled”.

d, the governing system in the ECM is

“Aux Press Sensor Installation Status”

Program auxiliary pressure sensor is installed. This will allow the display for the Engine Monitoring System (EMS) to monit this parameter to “Not Installed” if an auxiliary pressure sensor is not installed.

“Aux Press Enable” to “Installed” if an

or the pressure of another system. Program

Page 23

RENR5042-02 23

Troubleshooting Section

System Configuration Parameters

Table 9

System Configuration Parameters

Parameter Available Range or Options Default

ECM Identifi

cation Parameters

“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None

“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None

“ECM Serial Number” “Read Only”

(1)

“Software Gp Part Number” Software Dependent Read Only

“Software Gp Release Date” Software Dependent Read Only

Selected Engine Rating

“Rating Number” Software Dependent Customer

“Rated Power” Software Dependent Read Only

“Rated Peak Torque” Software Dependent Read Only

“Top Engine Speed Range” Software Dependent Read Only

“Test Spec” Software Dependent Read Only

“Top Eng

ine Limit”

Softwar

e Dependent

“Engine Accel. Rate” 50 to 1000 50 None

“Low Idle Speed” 600 to 1400 700 None

“PTO Mode”

dle Speed”

“High I

“Ramp Up/Ramp Down”

“Set/Resume”

“Ramp Up/Ramp Down” None

1800 to 2310 2310

“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” 1100 None

“Engine Power Trim” This parameter cannot be changed.

“Maximum Engine Torque Limit” Software Dependent None

“Customer Password #1” 8 alphanumeric characters Blank Customer

“Customer Password #2” 8 alphanumeric characters Blank Customer

“FLS” (Full Load Setting) -128to127

“FTS” (Full Torque Setting) -128 to 127

her Control”

“Et

“Air Shutoff”

“No Ether”

“Continuous Flow”

“Enabled”

“Disabled”

Ether”

“No

“Disabled”

“OFF”

“Auto Fuel”

“Maintenance Indicator Mode”

“Auto Hour”

“OFF” None

“Man Fuel”

“Man Hour”

“PM1 Interval”

“Throttle Position Sensor”

“Coolant Level On”

100 to 750 Hours

to 28390 L (1000 to 7500 US gal)

3785

“Installed”

“Not Installed”

“Installed”

“Not Installed”

250 Hours

L (2500 US gal)

9463

“Not Installed” None

Required

Password

Custome

Custom

Factory

None

tinued)

(con

(1)

Page 24

24 RENR5042-02 Troubleshooting Section

(Table 9, contd

)

System Configuration Parameters

Parameter Available Range or Options Default

“Direct Fuel Control Mode”

“Last Tool to change Customer Parameters”

“Last Tool to c hange System Parameters”

“Aux Temp Sensor Installation Status”

“Aux Press Sensor Installation Status”

“Installed”

“Not Installed”

Read Only

“On” “Off”

“Total Tattletale” Read Only

(1)

The parameter can only be viewed. No changes are allowed.

Parameters Worksheet

Note: A mistake in recording this information will

result in incorrect passwords.

Table 10

(Tab le 10, contd)

“Low Idle Speed”

TO Mode”

“P

Engine Parameters

ECM Identification Parameters

“Equipment ID”

“High Idle Speed”

“Intermediate Engine Speed”

“Engine Serial Number”

“Engine Power Trim”

Required

Password

“Not Installed” Factory

(1)

“Off” None

(1)

Engine Parameters

“ECM Serial Number”

“Software Gp Part Number”

“Software Gp Release Date”

elected Engine Rating

“Rating Number”

“Rated Power”

“Rated Peak Torque”

“Top Engine Speed Range”

“Test Spec”

“Top Engine Limit”

“Engine Accel Rate”

(continued)

“Maximum Engine Torque Limit”

Customer Password #1”

“

“Customer Password #2”

“FLS”

“FTS”

“Ether Control”

“Air Shutoff”

aintenance Indicator

“M Mode”

“PM1 Interval”

“Throttle Position Sensor”

“Coolant Level Sensor”

(continued)

Page 25

RENR5042-02 25

Troubleshooting Section

(Table 10, cont

“Direct Fuel Control Mode”

“Last Tool to change Customer Parameters”

“Last Tool to change System Parameters”

“Aux Press Temp Installation Status”

“Aux Press Sensor Installation Status”

“T otal Tattletale”

“Engine Serial Number”

“FLS”

“FTS”

Engine Paramet

Information from Engine Information Plate

Injector Codes

ers

Engine speed/timing sensors

•

Inlet air temperature sensor

•

Boost pressure

•

Coolant level sensor

•

Fuel temperature sensor

•

Fuel pressure

•

Auxiliary temperature sensor

•

Auxiliary pressure sensor

•

The monitorin

sensor

g system can be locked out. In order to change the settings, the monitoring system must be unlocked. Access the “Parameter Lockout” under the “Service”

menu on Cat ET in order to unlock the

monitoring system.

Warnings, de

rates, and shutdowns can be disabled

foranyparameterorforalloftheparameters.

Injector Code (1)

Injector Code (2)

Injector Code (3)

Injector Code (4)

Injector Code (5)

Injector Code (6)

Note: Compare the FLS and the FTS from the ECM with the values that are listed on the engine information plate. Only change the FLS and the FTS because of a mechanical change in the engine. The use of the wrong parameters could cause damage to the engine. The use of the wrong parameters may also void the Caterpillar warranty.

Monitoring System

The monitoring system determines the level of action that is taken by the ECM in response to a condition that can damage the engine. The monitoring of the various sensors by the ECM can be turned “On” or “Off”. These conditions are identified by the ECM from the signals that are produced from the following sensors:

Engine oil pressure sensor

•

Engine coolant temperature sensor

•

Page 26

26 RENR5042-02 Troubleshooting Section

Table 11

Settings for the Monitoring System

Parameter

Event

Code

E057 Derate On 1to54 10

“Low Coolant Level”

E058

E059 Warning

“High Fuel Pressure”

“Low Engine Oil Pressure”

“HighEngineCoolant

Temperature”

E096 Warning

E360

E361

“Engine Overspeed” E362

“High Fuel Temperature” E363

(2)

E443

“High Auxiliary

rature”

Te m pe

(2)

E445

Time Delay in

Action

Default

Value

Seconds

Range Default Range Default

Shutdown Off

1to54 10

None 8 Maps are not programmable.

Warning

On 8

Derate

Shutdown Off

None

Warning None 10

Derate

1to54 10

Shutdown Off 1to54 10

Warning

On None 1

Shutdown

Warning 1to54 30

Derate

Shutdown Off

1to54 10

Warning On 1to54 4

Derate 1to54 3“High Auxiliary Pressure”

Off

Shutdown

Warning

1to54 3

1to54 4

Derate 1to54 4

Off

Shutdown

1to54 4

Maps are not programmable.

85 °C (185 °F)

110°C(230°

86 °C (187 °F)

111 °C (232 °F)

87 °C (189 °F)

111 °C (232 °F)

C11/

C13

C15

C18

C11/

C13

C15

C18

70 °C (158 °F)

90 °C (194 °F)

71 °C (160 °F)

91 °C (196 °F)

0kPa(0psi)

3150 kPa (457 psi)

0°C(0

140 °C (284 °F)

Set Points

None

110 °C

(230 °F)

111 °C

(232 °F)

1800-2600 2600

1800-2500 2500

1800-2800 2800

1800-2700 2700

90 °C (194 °F)

91 °C (196 °F)

1500 kPa

(218 psi)

105 °C

(221 °F)

°F)

106 °C

(223 °

107 °C

(224 °F)

(continued)

(1)

Page 27

RENR5042-02 27

Troubleshooting Section

(Table 11, cont

Settings for the Monitoring System

Parameter

“High Engine Air Inlet

Temperature”

(1)

The maps may b e different. The maps d epend on the model of the engine.

(2)

The engine must be equipped with the appropriate sensor.

Event

Code

E539

Action

Warning None 8

Derate

Default

Value

Time Delay in

Seconds

Range

Default

1to54 8

Range

None

Set Points

Default

75 °C (167 °F)

79 °C (174 °F)

Page 28

28 RENR5042-02 Troubleshooting Section

Troubleshooti

ng without a

Diagnostic Code

Alternator (Charging Problem)

SMCS Code: 1405-035

Probable Causes

Alternator drive belts

•

Charging circuit

•

Regulator

•

Alternator

•

Recommended Actions

Alternator Drive Belts

i02119218

Probable Causes

Battery

•

An electrical device drains the battery.

•

Recommended Actions

Battery

1. Verify that the battery is no longer able to hold a

charge.

2. Replace the battery.

Electrical Device

1. Verify that an electrical device drained the battery

by being left in the ON position.

2. Charge the battery.

3. Verify that the battery is able to maintain a charge.

i02290338

1. Inspect the condition of the alternator drive belts. If the alternator drive belts are worn or damaged, replace the belts.

2. Check the tension on the alternator drive belts. Adjust the tension, if necessary.

Charging Circuit

Inspect the battery cables, wiring, and connections in the charging circuit. Clean all connections and tighten all connections. Replace any faulty parts.

Alternator or Regulator

Verify that the alternator or the regulator is operating correctly. Refer to Special Instruction, REHS0354, “Charging System Troubleshooting” for the proper testing procedures. Repair the alternator or replace the alternator, as needed.

i02170483

Battery

SMCS Code: 1401-035

Can Not Reach Top Engine RPM

SMCS Code: 1915-035

Note: If this

Troubleshooting, “Low Power/Poor or No Response to Throttle”.

The connection of any electrical equipment and the discon cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or dis explosive atmosphere.

Probable Causes

Diagnosti

•

Event codes

•

Programmable parameters

•

problem occurs only under load, refer to

nection of any electrical equipment may

connect any electrical equipment in an

c codes

Note: This is not an electronic system problem.

Refer to Special Instruction, REHS0354, “Charging System Troubleshooting” for the proper testing procedures.

Cold mode

•

Altitude derate

•

Throttle signal

•

Page 29

RENR5042-02 29

Troubleshooting Section

Rated fuel position and/or FRC fuel position

•

Boost pressure sensor

•

Fuel supply

•

Air inlet and exhaust system

•

Accessory equipment

•

Recommended Actions

Diagnostic Co

Certain diagnostic codes and/or event codes may cause poor per Electronic Technician (ET) and check for active codes and logged codes. Troubleshoot any codes that are present befor

Programmable Parameters

Check the following parameters on Cat ET:

“Throttle Po

•

“Desired Speed Input Configuration”

•

“Direct Fuel Control Mode”

•

Determine th application. Program the parameters to match the type of throttle that is used. Refer to Troubleshooting, “Throttle Po information.

Note: The en parameters are not programmed correctly.

des and Event Codes

formance. Connect the Caterpillar

econtinuingwiththisprocedure.

sition Sensor”

etypeofthrottlethatisusedinthe

sition Sensor Circuit - Test” for more

gine will have poor performance if the

Throttle Signal

Connect Cat ET to the service tool connector. View the status for the throttle position on the status screen. Opera position to the High Idle position. The status should be 0 percent at low idle and the status should be 100 percent at hi in the full range, refer to Troubleshooting, “Throttle Position Sensor - Calibrate”.

Diagnostic codes that are related to the J1939 data link will prevent correct operation of the throttle if the throttle pos there is a problem with the data link, the engine will remain at low idle until the data link is repaired.

te the throttle from the Low Idle

gh idle. If the status can not operate

ition is transmitted over the data link. If

Boost Pressure Sensor, Rated Fuel Position and/or FRC Fuel Position

1. With the engine at full load, monitor “Fuel Position”

and “Rated Fuel Limit” on the status screen. If “Fuel Posi then check air inlet manifold pressure.

2. Verify tha that are associated with the boost pressure sensor or with the atmospheric pressure sensor.

3. Monitor boost pressure and atmospheric pressure on the status screen for normal operation.

Note: Atmospheric pressure is not a default parameter on a status screen. You must manually select th order to monitor the atmospheric pressure sensor.

Fuel Supp

tion” does not equal “Rated Fuel Limit”

t there are no active diagnostic codes

e parameter for the atmospheric pressure in

Cold Mode

Use the electronic service tool to verify that the engine has e appear if the engine is operating in cold mode. This may limit engine speed.

xited cold mode. A status flag will

Altitude Derate

The engine Connect Cat ET to the service tool connector. Check for an active engine derate on the status screens.

Note: There are no event codes that are associated with the altitude derate.

may be derated due to high elevation.

1. Check the fuel lines for the following problems: restrict problems are found with the fuel lines, repair the lines and/or replace the lines.

2. Check the fuel tank for foreign objects which may block the fuel supply.

3. Check for air in the low pressure fuel supply system if any of the following procedures have been per

•

4. Purge air from the low pressure fuel supply circuit. Refer to “Fuel System - Prime” for the correct procedure.

ions, collapsed lines, and pinched lines. If

formed:

Replacement of the fuel filters

Service o n the low pressure fuel supply circuit

Replace

ment of unit injectors

Operation and Maintenance Manual,

Page 30

30 RENR5042-02 Troubleshooting Section

Note: A sight glass in the low pressure supply line is helpful in diag

5. Cold weather adversely affects the characteristics of the fuel. Re Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation.

6. Check the fuel pressure during engine cranking. Check the fue the fuel filter. Refer to Specifications for correct pressure values. If the fuel pressure is low, replace the f low, check the following items: fuel transfer pump, fuel transfer pump coupling, and fuel pressure regulating

nosing air in the fuel.

fer to the Operation and

l pressure on the outlet side of

uel filters. If the fuel pressure is still

valve.

Air Inlet and Exhaust System

1. Clean plugged air filters or replace plugged air

filters. Refer to the Operation and Maintenance Manual.

2. Check the air inlet and exhaust system for restricti Adjusting, “Air Inlet and Exhaust System”.

Accessory

Check all accessory equipment for problems that may create any damaged components or replace any damaged components.

ons and/or leaks. Refer to Testing and

Equipment

excessive load on the engine. Repair

i02119298

Recommended Ac

tions

Engine Oil Cooler Core

1. Check for leaks in the oil cooler core. If a leak is

found, install a new oil cooler core. Refer to the Disassembly a

2. Drain the crankcase and refill the crankcase with clean engine o Refer to the Operation and Maintenance Manual.

Cylinder Head

1. Remove the cylinder head. Refer to the

Disassembly

2. Check the cylinder liner projection. Refer to the Te s ti ng a n d A

3. Install a new cylinder head gasket and new water seals in the s and Assembly manual.

Cylinder He

Check for cracks in the cylinder head. If a crack is found, re the cylinder head. Refer to the Disassembly and Assembly manual.

nd Assembly manual.

il. Install new engine oil filters.

Gasket

and Assembly manual.

djusting manual.

pacer plate. Refer to the Disassembly

pair the cylinder head and/or replace

Cylinder Liner

Check for cr cracked cylinder liners. Refer to the Disassembly and Assembly manual.

acked cylinder liners. Replace any

Coolant in Engine Oil

SMCS Code

Probable

Engine oil cooler core

•

Cylinder head gasket

•

Cylinder

•

Cylinder liner

•

Cylinder block

•

: 1348-035; 1395-035

Causes

head

Cylinder Block

Inspect th found, repair the cylinder block or replace the cylinder block.

e cylinder block for cracks. If a crack is

i02194394

Coolant Temperature Is Too High

SMCS Code: 1395-035

Refer to Systems Operation/Testing and Adjusting, “Cooling System - Check” for information on determin

ing the cause of this condition.

Page 31

RENR5042-02 31

Troubleshooting Section

i02285862

ECM Will N ot Accept Factory Passwords

SMCS Code: 1901-035

Probable Causes

One of the foll correctly on the Caterpillar Electronic Technician (ET):

Passwords

•

Serial number

•

Total tattletale

•

Reason code

•

Recommended Actions

1. Verify that t

Check every character in each password. Remove the electrical power from the engine for 30 seconds and t

owing items may not be recorded

he correct passwords were entered.

hen retry.

Electronic Control Module (ECM)

•

Recommended Actions

1. Connect the electronic service tool to the

service tool connector. If the ECM does not communicate w to Troubleshooting, “Electronic Service Tool Will Not Communicate with ECM”.

2. Troubleshoot the Cat Data Link for possible problems. Refer to Troubleshooting, “Cat Data Link Circuit

3. Troubleshoot the CAN data link (if equipped) for possible pro “CAN Data Link Circuit - Test”.

ith the electronic service tool, refer

-Test”.

blems. Refer to Troubleshooting,

i02254038

Electronic Service Tool Will Not Communicate with ECM

SMCS Code: 0785-035; 1901-035

Probable Causes

2. Verify that the Cat ET is on the “Factory Password”

screen.

3. Use Cat ET to verify that the following information has been ente

Engine serial number

•

Serial number for the electronic control module

•

Serial numb

•

Total tattletale

•

Reason code

•

red correctly:

er for Cat ET

i02279167

ECM Will No t Communicate with Other S yste ms or Display Modules

SMCS Code: 1901-035

Probable Causes

Configurat

•

Electrical connectors

•

Communication adapter and/or cables

•

Electrical

•

connector

Caterpilla

•

hardware

Electrical

•

Module (ECM)

Flash file

•

Cat Data Link

•

ion for the communications adapter

power supply to the service tool

r Electronic Technician (ET) and related

power supply to the Electronic Control

Recommended Actions

Start the engine. If the engine starts, but the ECM will not communicate with Cat ET, continue with this proce Troubleshooting, “Engine Cranks but Will Not Start”. If the engine will not crank, refer to Troubleshooting, “Engine W

dure. If the engine will not start, refer to

ill Not Crank”.

Wiring and/or electrical connectors

•

Cat Data Li

•

CAN data link (if equipped)

•

Configuration for the Communications Adapter

1. Access “Preferences” under the “Utilities” menu

on Cat ET.

Page 32

32 RENR5042-02 Troubleshooting Section

2. Verify that the correct “Communications Interface Device” is sele

3. Verify that the correct port is selected for use by the communica

Note: The most commonly used port is “COM 1”.

4. Check for any hardware that is utilizing the

same port as the communications adapter. If any devices are co or close the software programs for that device.

Electrical C

Check for correct installation of the J1/P1 and J2/P2 ECM connecto Refer to Troubleshooting, “Electrical Connectors Inspect”.

cted.

tion adapter.

nfigured to use the same port, exit

onnectors

rs and of the service tool connector.

Communication Adapter and/or Cables

1. If you are us

ensure that the firmware and driver files for the communication adapter are the most current files that are ava do not match, the communication adapter will not communicate with Cat ET.

ing a “Communication Adapter II”,

ilable. If the firmware and driver files

Electrical Power Supply to the Electronic Control Module

Check power to the ECM. Refer to Troubleshooting, “Electrical P

Note: If the ECM is not rec eiving battery voltage, the ECM will not co

ower Supply Circuit - Test”.

(ECM)

mmunicate.

Flash File

Ensure that the correct flash file is properly installed in the ECM.

Note: The new ECM does not have a flash file. The engine will not start and the engine will not communicate been installed. Refer to Troubleshooting, “Flash Programming”.

with Cat ET until the flash file has

Cat Data Link

Troublesho Refer to Troubleshooting, “Cat Data Link Circuit Tes t” .

ot the Cat Data Link for possible problems.

i02290294

2. Disconnect the communication adapter and the cables from the service tool connector. Reconnect the commun connector.

3. Verify tha the communication adapter and the service tool connector. Refer to Troubleshooting, “Electronic Service T

ication adapter to the service tool

t the correct cable is being used between

ools”.

Electrical Power Supply to the Service Tool Conn

Verify that battery voltage is present between terminal communication adapter is not receiving power, the display on the communication adapter will be blank.

ector

s A and B of the service tool connector. If the

Cat ET and Related Hardware

In order as the problem, connect Cat ET to a different engine. If the same problem occurs on a different engine, check Ca determine the cause of the problem.

to eliminate Cat ET and the related hardware

t ET and the related hardware in order to

Engine Cranks but Will Not Start

SMCS Code: 1000-035

Probable Causes

Electrical power to the Electronic Control Module

•

(ECM)

Flash file

•

Remote shu

•

Air shutoff circuit

•

Starting motor solenoid or starting circuit

•

Engine spe

•

Electrical connections to the electronic unit injector

•

Fuel supply

•

Combustio

•

tdown switch

ed/timing sensors

n problem

Page 33

RENR5042-02 33

Troubleshooting Section

Recommended Ac

tions

Electrical Power to the ECM

1. Turn the keyswitch OFF.

2. Check the posit

connections to the ECM.

3. Perform a pull negative battery wires.

4. Check the nega engine ground.

5. Turn the keysw

6. The warning lamps should illuminate for five

seconds.

If the warning lamp illuminates for five seconds, continue wit

If the warning lamp does not illuminate for five seconds, ref Supply Circuit - Test”.

ive battery and negative battery

test on positive battery wires and

tive battery connection to the

itch ON.

h this procedure.

er to Troubleshooting, “Electrical Power

Starting Motor Solenoid or Starting Circuit

1. Test the operation of the starting motor solenoid.

2. Check the engine wiring to the starting motor

solenoid.

3. Test the operation of the starting motor.

4. Inspect the st

ring gear for damage.

Engine Speed/

Observe the engine speed on Cat ET while the engine is bein

Thissituationmayrequireadirecthookuptothe batteries in cranking. Refer to Illustration 9 for the wiring diagram.

arter motor pinion and the flywheel

Timing Sensors

g cranked.

order to power Cat ET while the engine is

Flash File

If a new ECM has been installed on the engine, the engine will n with the Caterpillar Electronic Technician (ET) until the correct flash file has been loaded into the ECM.

Check for a 253-02 Personality Module mismatch diagnostic code. If the code is active, load the correct flashfilei “Flash Programming”.

Remote Shu

Access the screen on Cat ET that displays the remote shutdown s status on Cat ET is called “User Shutdown”.

Table 12

Shutdown

Status”

ot start. The ECM will not communicate

nto the ECM. Refer to Troubleshooting,

tdown Switch

witch status. The remote shutdown switch

“User

Switch Status

ON Negative battery <0.9 VDC

OFF Open circuit >10 VDC

Measured

Voltage at P1-44

or P6-27

If the voltage is not in the proper range, refer to Troubleshooting, “Remote Shutdown Switch Circuit Tes t” .

Air Shutoff Circuit

Refer to Troubleshooting, “Air Shutoff System - Test” for additional information.

Page 34

34 RENR5042-02 Troubleshooting Section

Illustration 9

Direct connection of Cat ET to the P1 connector

If the engine is cranking and Cat ET displays zero rpm, a problem exists in the circuits for the engine speed/timing sensors. Refer to Troubleshooting, “Engine Speed/Timing Sensor Circuit - Test”.

If an engine speed is present, check the sensor installation. If the sensor is not properly installed, the ECM may read engine speed, but the ECM cannot determine the tooth pattern. The ability for the ECM to read the tooth pattern is necessary to determine the cylinder position. Engine speed is present when engine speed is greater than 50 rpm. Refer to Troubleshooting, “Engine Speed/Timing Sensor Circuit - Test”.

Electrical Connections to the Electronic Unit Injector

1. Ensure that the electronic unit injector connector

(J300/P300) is fully connected and free of corrosion.

2. Check for logged diagnostic codes that are related to the cylinder. Refer to Troubleshooting, “Injector Solenoid Circuit - Test” if diagnostic codes that are related to the cylinder are present.

g00781203

If no smoke is present, there may be a problem with the fuel quality or there may be a problem with the fuel supply.

3. Check the fuel pressure. Refer to Systems Operation/Testing and Adjusting, “Fuel System Pressure - Test”.

4. Ensure that the fuel system has been primed. Refer to Systems Operation/Testing and Adjusting, “Fuel System - Prime”.

5. Check for fuel supply lines that are restricted.

6. Check the fuel filters.

7. Cold weather adversely affects the characteristics

of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation.

Check for Combustion Problems

Examples of conditions that may cause combustion problems are shown in the following list:

Check the Fuel Supply

1. Check the fuel level.

2. Monitor the exhaust for smoke while the engine

is being cranked.

Cold temperatures

•

Injector misfiring

•

Low compression

•

Mechanical problem

•

Valvelashsettings

•

Page 35

RENR5042-02 35

Troubleshooting Section

Refer to the engine’s Systems Operation/Testing and Adjusting f problem.

Engine Has Ear

SMCS Code: 1000-035

ormoreinformationonaparticular

i02170800

ly Wear

Probable Causes

Incorrect engine oil

•

Contaminate

•

Contaminated air

•

Contaminated fuel

•

Low oil press

•

Recommended

Incorrect Engine Oil

d engine oil

ure

Actions

Low Oil P ressure

When some components of the engine show bearing wear in a short time, the cause can be a restriction in a passage for e

An indicator for the engine oil pressure may indicate sufficient pr to a lack of lubrication. In such a case, look at the passage for the engine oil supply to the component. Refer to Syst “Lubrication System” for additional information.

ngine oil.

essure, but a component is worn due

ems Operation/Testing and Adjusting,

i02290324

Engine Misfires, Runs Rough or Is Unstable

SMCS Code: 1000-035

Note: If the symptom is intermittent and the symptom

cannot be repeated, refer to Troubleshooting, “Intermittent Low Power or Power Cutout”. If the symptom is consistent and the symptom can be repeated, continue with this procedure.

Use engine oil that is recommended and change the engine oil at the interval that is recommended by the engine’s Ope

ration and Maintenance Manual.

Contaminated Engine Oil

Drain the crankcase and refill the crankcase with clean engine oil. Install new engine oil filters. Refer to the engin for more information.

If the oil fi filtered. Check the oil filter bypass valve for a weak spring or for a broken spring. If the spring is broken, replace th and Assembly manual. Make sure that the oil bypass valve is operating correctly.

e’s Operation and Maintenance Manual

lter bypass valve is open, the oil will not be

e spring. Refer to the engine’s Disassembly

Contaminated Air

Inspect th the gaskets and the connections. Repair any leaks.

Inspect t

e air inlet system for leaks. Inspect all of

he air filter. Replace the air filter, if necessary.

Contaminated Fuel

Inspect the fuel filter. Replace the fuel filter, if necessary.

Contaminants in the fuel such as hydrogen sulfide and sulfur can lead to the formation of acids in the crankcas

e. Obtain a fuel analysis.

Probable Causes

Diagnostic codes

•

Programmable parameters

•

Electrical connectors

•

Cold mode

•

Throttle signal

•

Unit injectors

•

Fuel supply

•

Air inlet and exhaust system

•

Recommended Actions

Note: If the symptom only occurs under certain

operating conditions (high idle, full load, engine operating temperature, etc), test the engine under those conditions. Troubleshooting the symptom under other conditions can give misleading results.

Diagnostic Codes

Check for active diagnostic codes on the Caterpillar Electronic Technician (ET). Troubleshoot any active codes before continuing with this procedure.

Programmable Parameters

Check the following parameters on Cat ET:

Page 36

36 RENR5042-02 Troubleshooting Section

ThrottlePositionSensor

•

Desired Speed Input Configuration

•

Direct Fuel Con

•

Determine the type of throttle that is used in the application. type of throttle that is used. Refer to Troubleshooting, “Throttle Position Sensor Circuit - Test” for more information.

Note: The engine will have poor performance if the parameters a

trol Mode

Program the parameters to match the

re not programmed correctly.

Electrical Connectors

Check for correct installation of the Electronic Control Module (ECM) connectors and the unit injector connectors. Connectors - Inspect”.

Refer to Troubleshooting, “Electrical

Cold Mode

Use Cat ET to verify that the engine has exited cold mode. Cold m run rough and the engine power may be limited.

Throttle Si

Monitor the throttle signal on Cat ET. Verify that the throttle si thehighidleposition.

Unit Injec

1. Use Cat ET to determine if there are any active

diagnosti

2. Perform the injector solenoid test on Cat ET in order to de are being energized by the ECM. Refer to Troubleshooting, “Injector Solenoid Circuit - Test” for the pro

3. Perform the cylinder cutout test on Cat ET in order to identif Refer to Troubleshooting, “Injector Solenoid Circuit - Test” for the proper procedure.

ode operation may cause the engine to

gnal

gnal is stable from the low idle position to

tors

c codes for the unit injectors.

termine if all of the injector solenoids

per procedure.

y any injectors that might be misfiring.

3. Check for air in the low pressure fuel supply system if any of been performed:

Replacement o

•

Service o n the low pressure fuel supply circuit

•

Replacement of unit injectors

•

4. Purge air from Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the complete procedure.

Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel.

5. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance the characteristics of the fuel during cold weather operation.

6. Check the fuel pressure during engine cranking. Check the fuel pressure after the fuel filter. Refer to Systems O System” for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel pressure is transfer pump, fuel transfer pump coupling, and fuel pressure regulating valve.

the following procedures have

f the fuel filters

the low pressure fuel supply circuit.

Manual for information on improving

peration/Testing and Adjusting, “Fuel

still low, check the following items: fuel

Air Inlet and Exhaust System

1. Check for a

filters or replace plugged air filters. Refer to the Operation and Maintenance Manual for additional informat

2. Check the air inlet and exhaust system for restrict Operation/Testing and Adjusting, “Air Inlet and Exhaust System”.

n air filter restriction. Clean plugged air

ion.

ions and/or for leaks. Refer to Systems

i02173692

Engine Oil in Cooling System

SMCS Code: 1348-035; 1350-035

Fuel Supply

1. Check the

restrictions, collapsed lines, and pinched lines. If problems are f ound with the fuel lines, repair the lines an

2. Check the fuel tank for foreign objects which may block th

fuel lines for the following problems:

d/or replace the lines.

e fuel supply.

Probable Causes

Engine oil cooler core

•

Cylinder head gasket

•

Page 37

RENR5042-02 37

Troubleshooting Section

Recommended Ac

tions

Engine Oil Cooler C ore

1. Inspect the engine oil cooler core for leaks. If a

leak is found, replace the oil cooler core. Refer to Disassembly a Remove”.

2. Drain the cran clean engine oil. Install new engine oil filters. Refer to the Operation and Maintenance Manual for more info

nd Assembly, “Engine Oil Cooler -

kcase and refill the crankcase with

rmation.

Cylinder Head Gasket

1. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove” for the correct proc

2. Check the cylinder liner projection. Refer to Systems Ope correct procedure.

3. Install a ne seals in the spacer plate. Refer to Disassembly and Assembly, “Cylinder Head - Install” for the correct pro

edure.

ration/Testing and Adjusting for the

w cylinder head gasket and new water

cedure.

Engine Oil Temperature Reading

Compare the engine oil temperature reading from the Caterpillar Electronic Technician (ET) to the temperature f (MULTIMETER). Verify that the readings are reasonably close.

rom a 6V-9130 Temperature Adapter

Coolant temperature

If a high coola occurring, refer to Troubleshooting, “Coolant Temperature is Too High”.

nt temperature condition is also

Engine Oil Cooler Bypass Valve

Clean the eng the engine oil cooler bypass valve. Clean the bore for the valve. Ensure that the bypass valve is not stuck in the open po necessary.

Engine Oil C

Clean the engine oil cooler core or replace the engine oil cooler c

ine oil cooler bypass valve and inspect

sition. Replace the bypass valve, if

ooler Core

ore.

i02253823

i02214225

Engine Oil Temperature Is Too High

SMCS Code: 1348-035-TA

Probable Causes

Engine oil level

•

Engine oil

•

Coolant temperature

•

Engine oil cooler bypass valve

•

Engine oil

•

Recommen

Engine Oil Level

Inspect the engine oil level. If necessary, add oil.

temperature reading

cooler core

ded Actions

Engine Stal

SMCS Code: 1915-035

ls at Low RPM

Probable Causes

Unit injectors

•

Fuel supply

•

Accessory equipment

•

Recommended Actions

Unit Injectors

1. Check for co

J2/P2 connectors for the Electronic Control Module (ECM). Check for correct installation of the J300/P Refer to Troubleshooting, “Electrical Connectors

- Inspect”.

2. Perform the “Injector Solenoid Test” with the Caterpillar Electronic Technician (ET) in order to determin energized by the ECM.

rrect installation of the J1/P1 and

300 connectors for the unit injectors.

e if all of the injector solenoids are being

3. Perform t in order to identify any injectors that might be misfiring. Refer to Troubleshooting, “Injector Solenoid

he “Cylinder Cutout Test” with Cat ET

Circuit - Test” for the proper procedure.

Page 38

38 RENR5042-02 Troubleshooting Section

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation/Testing and Adjusting, “Fuel System” for the correc

2. Check the fuel lines for the following problems: restrictions problems are f ound with the fuel lines, repair the lines and/or replace the lines.

3. Check the fuel tank for foreign objects which may block the fuel supply.

4. Check for air in the low pressure fuel supply system if any of the following procedures have been perform

Replacement of the fuel filters

•

Service on the low pressure fuel supply circuit

•

Replacement

•

Note: A sight glass in the low pressure supply line is helpful in d Operation/Testing and Adjusting, “Fuel System” for more information.

t procedure.

, collapsed lines, and pinched lines. If

ed:

of unit injectors

iagnosing air in the fuel. Refer to Systems

i02214232

Engine Vibration

SMCS Code: 1000

Probable Cause

Vibration damper

•

Engine supports

•

Driven equipm

•

Engine misfiring or running rough

•

Recommended Actions

Vibration Damper

Check the vibr new vibration damper, if necessary. Inspect the mounting bolts for damage and/or for wear. Replace any damaged b Assembly manual.

Engine Suppo

-035

ent

ation damper for damage. Install a

olts. Refer to the Disassembly and

rts

NOTICE Do not crank 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

5. Purge air from the low pressure fuel supply circuit.

Refer to the Operation and Maintenance Manual, “Fuel Syst

6. Cold weather adversely affects the characteristics

of the fuel Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation

7. Check the fuel pressure after the fuel filter while

the engine Operation/Testing and Adjusting manual for the correct pressure values. If the fuel pressure is low, replace t low, check the following items: fuel transfer pump, fuel transfer pump coupling, and fuel pressure regulat

the engine continuously for more than

em - Prime” for the correct procedure.

. Refer to the applicable Operation and

is being cranked. Refer to the Systems

he fuel filters. If the fuel pres sure is still

ing valve.

Accessory Equipment

Check all accessory equipment for problems that may create excessive load on the engine. Repair any dama components.

ged components or replace any damaged

Inspect the mounts and the brackets while you run the engine th and brackets that are loose and/or broken. Tighten all of the mounting bolts. Install new components, if necessary.

rough the speed range. Look for mounts

Driven Equipment

Check the alignment and the balance of the driven equipment.

Engine Misfiring or Running Rough

Refer to Tro Rough or Is Unstable”.

ubleshooting, “Engine Misfires, Runs

i02214238

Engine Will Not Crank

SMCS Code: 1000-035

Probable Causes

Batteries

•

Battery cables

•

Starting circuit

•

Page 39

RENR5042-02 39

Troubleshooting Section

Starting motor solenoid

•

Starting motor

•

Flywheel ring g

•

Transmission

•

Engine accessories

•

Hydraulic cyl

•

Internal engine problem

•

ear

inder lock

Recommended Actions

Batteries and/or Battery Cables

1. Inspect the ma

and battery cables for loose connections and for corrosion. If the battery cables are corroded, remove the ba cables. Tighten any loose connections.

2. Inspect the b

a. Charge the batteries. Refer to Special

Instruction Procedure”.

b. Load test the

Instruction, SEHS9249, “Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batter

in power switch, battery posts,

ttery cables and clean the battery

atteries.

, SEHS7633, “Battery Test

batteries. Refer to Special

ies”.

The following list illustrates examples of engine accessories th

Hydraulic pump that is driven from the rear gear

•

group

Air compressor

•

Engine oil pump

•

Other compone

•

at may lock up the engine:

nts that are driven by the engine

Hydraulic Cylinder Lock

Check for fluid in the cylinders (hydraulic cylinder lock) by removing the individual unit injectors.

Note: Drain the fuel from the cylinder head. Fuel will flow from the cylinder head into the cylinders when the unit injec

tor is removed.

Internal Engine Problem

Disassemble the engine. Refer to the Disassembly and Assembly manual. Inspect the internal components f

Seizure

•

Broken components

•

Bent compone

•

or the following conditions:

nts

i02280902

Starting Motor Solenoid or Starting Circuit

1. Test the operation of the starting motor solenoid.

2. Check the wiring to the starting motor solenoid.

Starting Mo

1. Test the operation of the starting motor.

2. Inspect the starter motor pinion and the flywheel

ring gear for damage.

tor or Flywheel Ring Gear

Transmission or Engine Accessories

1. Ensure fre

2. Ensure that the timing pin was not left in the

flywheel h

3. Remove any engine accessories that may lock up

the engine that may lock up the engine.

e movement of the driveline.

ousing.

and inspect any engine accessories

Excessive Black Smoke

SMCS Code: 1088-035

Probable Causes

Air inlet an

•

Engine speed/timing sensor

•

Atmospheric pressure sensor

•

Boost press

•

“Fuel Position” and/or “FRC Fuel Limit”

•

Flash file

•

Fuel qualit

•

Valve adjustment

•

d exhaust system

ure sensor

Page 40

40 RENR5042-02 Troubleshooting Section

Recommended Ac

tions

Air Inlet and Exhaust System

1. Check the air inlet system for restrictions and/or

for leaks.

a. Check for an air filter restriction.

b. Check for dera

c. Perform a visual inspection of the system for

restrictions

2. Ensure that the turbocharger has not failed.

3. Check the exhaust system for restrictions.

4. Repair any lea

any restrictions that were found. Replace any damaged components that were found.

tes and for alarms.

and/or for leaks.

ks that were found. Remove

Engine Speed/Timing

1. Check the cal

sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor - Calibrate”.

2. Verify that the crankshaft and the camshaft drive

gears are set with the proper orientation. Refer to the Disassem

ibration of the engine speed/timing

bly and Assembly manual.

Note: A problem with the FRC will only cause black smoke during ac will not cause black smoke during steady state operation.

celeration. A problem with the FRC

Flash File

Verify that th to Troubleshooting, “Flash Programming” for more information.

ecorrectflashfileisinstalled.Refer

Fuel Quality

Cold weather the fuel. Refer to Operation and Maintenance Manual for information on improving the characteristics of the fuel during c

adversely affects the characteristics of

old weather operation.

Valve Adjustment

Check the valve adjustment. Refer to Systems Operation/Testing and Adjusting, “Air Inlet and Exhaust Sys

tem”.

i01405645

Excessive Engine Oil Consumption

SMCS Code: 1348-035

Atmospheric Pressure Sensor

Check the atmospheric pressure sensor for dirt and/or for debris. Remove any dirt and/or debris that is present. pressure is between 50 kPa (7.25 psi) and 100 kPa (14.5 psi).

The correct reading for the atmospheric

Boost Pressure Sensor, “Fuel Position”, and/or “FRC Fuel Limit”

1. Monitor the status of “Fuel Position” and “Rated

Fuel Limit” while the engine is operating under full load.If“F and “Fuel Position” is less than “FRC Fuel Limit”, the electronics are operating correctly. Otherwise, proceed t

2. Verify that there are no active diagnostic codes for

the boost

3. Monitor the status of “Boost Pressure” and

“Atmosph the Caterpillar Electronic Technician (ET). When the engine is not running, “Boost Pressure” should be 0 kPa (0

uel Position” equals “Rated Fuel Limit”

o the next Step.

pressure sensor.

eric Pressure” for normal operation on

psi).

Probable Causes

Oil leaks

•

Oil level

•

Engine oil temperature

•

Turbocharger

•

Valve guides

•

Piston rings

•

Recommended Actions

Oil Leaks

Locate all oil leaks. Repair the oil leaks. Check for dirty crankcase breathers.

Oil Level

Remove excess oil. Locate the source of the excess fluid. Repair the leaks that are causing the problems. Recheck all fluid levels.

Page 41

RENR5042-02 41

Troubleshooting Section

Engine Oil Temperature

Refer to Troubleshooting, “Engine Oil Temperature is Too High”.

Turbocharger

Check the air i the turbocharger or replace the turbocharger.

nlet manifold for oil. If necessary, repair

Valve Guides

If the valve guides are worn, reconditioning of the cylinder head

is required.

Piston Rings

Inspect the internal engine components. Replace any worn components.

i02253900

Excessive Fuel C on sumption

SMCS Code: 12

50-035

Fuel Leaks

Check the fuel pressure during engine cranking. Check the fuel pressure after the fuel filter. Refer to Systems Ope System” for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel pressure is s transfer pump, fuel transfer pump coupling, and fuel pressure regulating valve.

ration/Testing and Adjusting, “Fuel

till low, check the following items: fuel

Fuel Quality

Cold weather of the fuel. Refer to the applicable Operation and Maintenance Manual for information on improving the characte operation.

Engine Spee

Calibrate the engine speed/timing sensors. Refer to Troubles

-Calibrate”.

Unit Inject

adversely affects the characteristics

ristics of the fuel during cold weather

d/Timing

hooting, “Engine Speed/Timing Sensor

ors

Probable Cau

Engine operation

•

Fuel leaks

•

Fuel quality

•

Engine speed/timing

•

Unit injectors

•

Air inlet an

•

Accessory equipment

•

d exhaust system

ses

Recommended Actions

Engine Operation

Use the Cate check the “Current Totals” for excessive idle time and/or for a high load factor which would be indicative of poor ope

Note: Engine operation may also be affected by environme

rpillar Electronic Technician (ET) to

rating habits.

ntal conditions such as wind and snow.

1. Check for correct installation of the J1/P1 and J2/P2 E connectors and the unit injector connectors. Refer to Troubleshooting, “Electrical Connectors

- Inspect”

2. Perform the “Injector Solenoid Test” on Cat ET in order to de are being energized by the ECM.

3. Perform t in order to identify any injectors that might be misfiring. Refer to Troubleshooting, “Injector Solenoid

lectronic Control Module (ECM)

termine if all of the injector solenoids

he “Cylinder Cutout Test” on Cat ET

Circuit - Test” for the proper procedure.

Air Inlet and Exhaust System

1. Inspect the air filter for a restriction. If the air filter

shows signs of being plugged, clean the air filter or replac

2. Check the air inlet and exhaust system for restric Operation/Testing and Adjusting, “Air Inlet and Exhaust System”.

e the air filter.

tions and/or for leaks. Refer to Systems

Accessory Equipment

Check al may create excessive load on the engine. Repair any damaged components or replace any damaged compon

l accessory equipment for problems that

ents.

Page 42

42 RENR5042-02 Troubleshooting Section

i02280972

Excessive Valve Lash

SMCS Code: 1105

Probable Cause

Lubrication

•

Valve lash

•

Valve tr ain co

•

Recommended A

Lubrication

1. Remove the valve mechanism covers. Refer to

the engine’s Disassembly and Assembly manual for the corre

2. Check the lubrication in the valve compartment. Ensure that t the valve compartment. The passages for the engine oil must be clean.

-035

mponents

ctions

ct procedure.

here is adequate engine oil flow in

3. Adjust the engine valve lash. Refer to the engine’s Systems Operat for the correct procedure.

Excessive Whi

SMCS Code: 1088-035

Note: Some white smoke may be present during

cold start-up conditions when the engine is operating normally. If a problem.

the white smoke persists, there may be

ion/Testing and Adjusting manual

i02290300

te Sm oke

Probable Causes

Diagnostic c

•

Starting aids

•

Water temperature regulators

•

Unit inject

•

Flash file

•

odes

ors

Valve Lash

Adjust the en Systems Operation/Testing and Adjusting manual for the correct procedure.

gine valve lash. Refer to the engine’s

Valve Train Components

1. Inspect the

train:

Rocker arms

•

Pushrods

•

Valve lifters

•

Camshaft

•

Valve stems

•

Rocker shafts

•

2. Check the co abnormal wear, excessive wear, straightness, and cleanliness. Replace parts, if necessary.

following components of the valve

mponents for the following conditions:

Fuel supply

•

Cooling syst

•

Component wear

•

Recommended Actions

Diagnostic Codes

Check for ac Electronic Technician (ET). Troubleshoot any active codes before continuing with this procedure.

Starting Aids

Air Inlet He

Ensure that the air inlet heater is functioning properly. For additio “Air Inlet Heater Circuit - Test”.

Ether Inje

Ensure that the ether injection system is programmed to “On”.

tive diagnostic codes on the Caterpillar

ater (If Equipped)

nal information, refer to Troubleshooting,

ction System (If Equipped)

Note: If you replace the camshaft, you must also

replace the valve lifters.

Ensure that the ether injection system is functioning properly. Troubleshooting, “Ether Injection System - Test”.

For additional information, refer to

Page 43

RENR5042-02 43

Troubleshooting Section

Water Temperature Regulators

Check the water temperature regulators for correct operation. Refer to Systems Operation/Testing and Adjusting, “C

ooling System” for the proper procedure.

Unit Injectors

Use Cat ET to perform the cylinder cutout test. Try to simulate the conditions for the test that were experienced d individually for approximately one minute in order to isolate any misfiring cylinders. If the misfire can be isolat Troubleshooting, “Injector Solenoid Circuit - Test”.

uring operation. Cut out each cylinder

ed to a specific cylinder, proceed to

Flash File

Verify that the correct flash file is installed. The flash file that is i (ECM) will be displayed on the “Configuration” screen on Cat ET.

nstalled in the Electronic Control Module

Fuel Supply

1. Monitor the

is being cranked.

If no smoke i with the fuel quality or there may be a problem with the fuel supply.

exhaust for smoke while the engine

s present, there may be a problem

Pistons

•

Rings

•

Cylinder liner

•

i02214294

Exhaust Temperature Is Too High

SMCS Code: 1088-035-TA

Probable Causes

Diagnostic codes

•

Electrical connectors

•

Air inlet and exhaust system

•

Recommended Actions

Diagnostic Codes

Connect the Caterpillar Electronic Technician (ET) and check for active diagnostic codes. Troubleshoot any active diagnostic codes before continuing with this procedure.

2. Check the fuel pressure. Refer to Systems Operation/Testing and Adjusting, “Fuel System Pressure -

3. Ensure that the fuel system has been primed. Refer to Sy “Fuel System - Prime”.

4. Check for f

5. Cold weather adversely affects the characteristics

of the fue Maintenance Manual for information on improving the characteristics of the fuel during cold weather operatio

Te s t” .

stems Operation/Testing and Adjusting,

uel supply lines that are restricted.

l. Refer to the Operation and

Cooling System

Check for an internal coolant leak. Check for coolant in the engine oil, coolant in the cylinders, and coolant Operation/Testing and Adjusting, “Cooling System Tes t” .

in the exhaust system. Refer to Systems

Component Wear

Electrical Connectors

Check for correct installation of the J2/P2 Electronic Control Module (ECM) connector and of the J300/P300 unit injector connectors. Refer to Troubleshooting, “Electrical Connectors - Inspect” for more information.

Air Inlet and Exhaust System

1. Check the air inlet manifold pressure. Check for

air inlet restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting, “Air Inlet and Exhaust System” for more information.

2. Check for leaks between the exhaust manifold and the turbocharger. Check for exhaust restrictions. Refer to Systems Operation/Testing and Adjusting, “Air Inlet and Exhaust System” for more information.

Check th

Valves

•

e following components for excessive wear:

Page 44

44 RENR5042-02 Troubleshooting Section

i01405833

Fuel in Cooling System

SMCS Code: 1350

Probable Cause

Internal cylinder head

•

Recommended Actions

Internal Cylinder Head

1. Remove the val

2. Remove the fuel supply and the fuel return line

from the cylin

3. Cap the fuel return connector and apply 700 kPa (100 psi) max connector. Check for fuel leakage around the unit injectors. If leakage is present, remove the unit injector and

-035

ve mechanism covers.

der head.

imum air pressure to the fuel supply

install a new O-ring seal.

Leaking Seals on the Fuel Line Adapter for the Cylinde

Look for signs of damage to the seals on the fuel line adapter for th lines or components and/or replace any leaking fuel lines or components.

rHead

e cylinder head. Repair any leaking fuel

Excessive Leakage from the Unit Injector Tip or Breakage of the Unit Injector Tip

Look for signs of damage to the unit injectors. If necessary, repair the unit injectors or replace the unit injectors.

Cracked Fuel Supply Manifold

Look for signs of damage to the fuel supply manifold.

Leaking Fuel

Ensure that the weep hole is not plugged. If necessary, the fuel transfer pump.

Transfer Pump Seal

repair the fuel transfer pump or replace

i02119587

Fuel Dilution of Engine Oil

SMCS Code: 1348-035

Probable Causes

Leaking seals on the case of the unit injector or on

•

the barrel of the unit injector

Leaking seals on the fuel line adapter for the

•

cylinder head

Excessive leakage from the unit injector tip or

•

breakage of the unit injector tip

Cracked fuel supply manifold

•

Leaking seal on the fuel transfer pump

•

Recommended Actions

Leaking Seals on the Case of the Unit Injector or on the Barrel of the Unit Injector

Look for signs of damage to the seals for the unit injectors. Replace any seals that are leaking.

i02290607

Intermitte

SMCS Code: 1000-035

Note: Use this procedure only if the engine shut

down completely and it was necessary to restart the engine.

Probable C

Diagnostic codes or event codes

•

Selected engine rating parameters

•

Electrica

•

Faulty remote shutdown

•

Circuit breakers

•

Fuel suppl

•

Faulty overspeed verify switch

•

Note: If the problem only occurs under certain conditions such as high engine speed, full load or engine op under those operating conditions.

nt Engine Shut do wn

auses

l connections

erating temperature, then perform the test

Page 45

RENR5042-02 45

Troubleshooting Section

Recommended Ac

tions

Diagnostic Codes or Event Codes

Certain diagnostic codes and/or event codes may cause the engine to shutdown. Connect the Caterpillar E active codes and/or for logged codes. Troubleshoot any codes that are present before continuing with this procedu

lectronic Technician (ET) and check for

re.

Selected Engine Rating Parameters

The engine may be shut down due to low pressure levels or other factors. Connect Cat ET and check for active shutd

If a shutdown is active, “Injection Disabled” will appear in the ET.

An engine sh device if the device is capable of displaying diagnostic codes.

owns or diagnostic codes.

third box of any status screen on Cat

utdown event will appear on a J1939

Electrical Connections

1. Check the fo

installation:

J1/P1 and J2

•

Control Module (ECM)

J61/P61 Cus

•

llowing connectors for proper

/P2 connectors for the Electronic

tomer connectors

Table 13

“User Shutdown” Status

ON <0.9 VDC

OFF >10 VDC

3. If the voltage is not in the proper range, refer to ubleshooting, “Switch Circuits - Test”.

Tro

Measured Voltage at

J1-44 or P61-27

Circuit Breakers

Check the circuit breakers. The circuit breakers may exceed the trip point due to overheating. Reset the

rcuit breakers if the circuit breakers are tripped.

Fuel Supply

Check for a problem with the fuel supply. Verify that the fuel pressure is correct. Verify that the

el pressure sensor is installed. Refer to Systems

fu Operation/Testing and Adjusting, “Fuel System” for additional information.

Faulty Overspeed Verify Switch (If Equipped)

A problem with the circuit for the overspeed verify feature may be causing the engine to shut down.

here are no diagnostic codes or event codes that

T are associated with the overspeed verify feature. Refer to Troubleshooting, “Switch Circuits - Test”.

J300/P300 Connectors for the injector solenoid

•

harness

J401/P401 and J402/P402 Engine speed/timing

•

sensor con

2. Check the associated wiring for the following condition incorrect attachment.

Refer to Tr

- Inspect”.

Note: Afte interrupt power to th e ECM. Check for correct installation and for operation of aftermarket engine protecti the aftermarket devices in order to continue testing.

on devices. It may be necessary to bypass

Faulty Re

1. Access the status screen that displays the remote

shutdown switch status on Cat ET is called “User Shutdown”.

2. Refer to each terminal that is listed and the engine ground.

nectors

s: damage, abrasion, corrosion, and

oubleshooting, “Electrical Connectors

rmarket engine protection devices usually

mote Shutdown

switch status. The remote shutdown

Table 13. Measure the voltage between

i02290319

Intermittent Low Power or Power Cutout

SMCS Code: 1000-035

Note: Use this procedure only if the engine does not

shut down completely.

Probable Causes

Diagnostic codes

•

Event codes

•

Throttle signal

•

Electrical connectors

•

Fuel supply

•

Page 46

46 RENR5042-02 Troubleshooting Section

Recommended Ac

tions

Diagnostic Codes and Event Codes

Certain diagnostic codes and/or event codes may cause poor performance. Connect the Caterpillar Electronic Te and logged codes. Troubleshoot any codes that are present before continuing with this procedure.

chnician (ET) and check for active codes

Throttle Signal

Connect Cat ET the status for the throttle position on the status screen. Operate the throttle from the low idle position tothehighid percent at low idle and the status should be 100 percent at high idle. Refer to Troubleshooting, “Throttle Po is incorrect.

Diagnostic link will prevent correct operation of the throttle if the throttle position is transmitted over the data link. If there is a p remain at low idle until the data link is repaired.

Electrica

1. Inspect the battery wires from the Electronic

Control Mo compartment. Refer to the Electrical System Schematic. Inspect the wires and the power relay. Check the p the ECM. Refer to the diagnostic functional test Troubleshooting, “Electrical Power Supply Circuit

- Test” fo

to the service tool connector. View

le position. The status should be 0

sition Sensor - Calibrate” if either value

codesthatarerelatedtotheJ1939data

roblemwiththedatalink,theenginewill

l Connectors

dule (ECM) back to the battery

ower and ground connections to

r more information.

Note: A sight glass in the low pressure supply line is helpful in diag Operation/Testing and Adjusting, “Fuel System” for more information.

Do not crank the 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

4. Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual, “Fuel System

5. Cold weather adversely affects the characteristics of the fuel. R Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation.

6. Check the fuel pressure after the fuel filter while the engine i Operation/Testing and Adjusting, “Fuel System Pressure - Test” for the correct pressure values. If the fuel p If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling, to Systems Operation/Testing and Adjusting, “Fuel System” for additional information.

nosing air in the fuel. Refer to Systems

NOTICE

engine continuously for more than

- Prime” for the correct procedure.

efer to the Operation and

s being cranked. Refer to Systems

ressure is low, replace the fuel filters.

and fuel pressure regulating valve. Refer

i02171503

Low Engin e Oil Pressu re

SMCS Code: 1348-035-LP

Fuel Supply

1. Check the fuel lines for the following problems:

restrictions, collapsed lines, and pinched lines. If problem lines and/or replace the lines.

2. Check th block the fuel supply.

3. Check fo system if any of the following procedures have been performed:

•

s are found with the fuel lines, repair the

e fuel tank for foreign objects which may

r air in the low pressure fuel supply

Replacement of the fuel filters

Service

Replacement of unit injectors

on the low pressure fuel supply circuit

NOTICE Do not operate the engine with low oil pressure. Engine damage will result. If measured oil pressure is low, discontinue engine operation until the problem is corrected.

Refer to Systems Operation/Testing and Adjusting, “Lubrication System” for information on engine oil pressure.

i02290611

Low Power/Poor or No Response to Throttle

SMCS Code: 1000-035

Probable Causes

Diagnostic codes

•

Page 47

RENR5042-02 47

Troubleshooting Section

Event codes

•

Engine rating

•

Programmable p

•

Cold mode

•

Altitude derate

•

Electrical co

•

PTO enable switch

•

Intermediate speed switch

•

Throttle sign

•

Circuit for electronic unit injectors

•

Fuel supply

•

Boost pressur

•

fuel position and/or FRC fuel position

Air inlet and e

•

arameters

nnectors

e sensor (intake manifold air), rated

xhaust system

Determine the type of throttle that is used in the application. P type of throttle that is used. Refer to Troubleshooting, “Throttle Position Sensor Circuit - Test” for more information.

Note: The engine will have poor performance if the parameters a

rogram the parameters to match the

re not programmed correctly.

Cold Mode

Monitor the status screen on Cat ET in order to verify that the engine has exited cold mode. Observe the reading for c engine should exit cold mode whenever the coolant temperature is above 18 °C (64 °F).

oolant temperature on Cat ET. The

Altitude Derate

Theenginema Connect Cat ET to the service tool connector. Check for an active engine derate on the status screens.

Note: There are no event codes that are associated with the altitude derate.

ybederatedduetohighelevation.

Recommended A

Note: If the problem only occurs under certain

conditions, t Examples of certain conditions are high rpm, full load and engine operating temperature. Troubleshooting the symptoms misleading results.

Diagnostic C

Certain diagnostic codes and/or event codes may cause poor p Electronic Technician (ET) and check for active codes and for logged codes. Troubleshoot any codes that are present

est the engine under those conditions.

under other conditions can give

odes and Event Codes

erformance. Connect the Caterpillar

before continuing with this procedure.

ctions

Engine Rating

Verify that the correct engine rating is being used for the application.

Programmable Parameters

Check the f

ThrottlePositionSensor

•

Desired Speed Input Configuration

•

Direct Fuel

•

ollowing parameters on Cat ET:

Control Mode

Electrical Connections to the Electronic Control Module (ECM)

Check the associated wiring for damage, abrasion, corrosion or incorrect attachment on the following connector J61/P61 customer connector (optional), and J403/P403 throttle position sensor connector. Refer to Troubl for additional information.

PTO Enabl

Connect Cat ET and verify that the “PTO Enable Switch” i parameter does not match the position of the switch, there is a problem with the circuit for the PTO enable switch. R Tes t” .

If the va matches the position of the switch, continue to next step.

s. J1/P1 and J2/P2 ECM connectors,

eshooting, “Electrical Connectors - Inspect”

eSwitch

s “Not Engaged”. If the value of the

efer to Troubleshooting, “Switch Circuits -

lue of the “PTO Enable Switch” parameter

Intermediate Spe ed Switch

Verify t Switch”matchesthepositionoftheswitch.Ifthe value of the parameter does not match the position of the s for the switch for the intermediate speed. Refer to Troubleshooting, “Switch Circuits - Test”.

hat the value of the “Intermediate Speed

witch, there is a problem with the circuit

Verify that the injector trim files are programmed.

Page 48

48 RENR5042-02 Troubleshooting Section

If the value of the “Intermediate Speed Switch” parameter matc continue to next step.

Throttle Sign

View the status for the throttle position on the status screen. Opera to the high idle position. The status should be 0 percent at low idle and the status should be 100 percent at hi the full range, refer to Troubleshooting, “Throttle Position Sensor - Calibrate”.

Diagnostic codes that are related to the J1939 data link will prevent correct operation of the throttle if the throttle pos thereisaproblemwiththedatalink,theenginewill remain at low idle until the data link is repaired.

hes the position of the switch,

tethethrottlefromthelowidleposition

gh idle. If the status cannot operate in

ition is transmitted over the data link. If

Circuit for the Electronic Unit Injector

Inspect the unit injector connector for proper connections. Refer to Troubleshooting, “ Electrical Connectors - Inspect”. Cut out eac cylinder or cylinders. If the results are inconclusive, shut off half of the cylinders and repeat the cylinder cutout tes in order to locate those cylinders that are missing. Refer to Troubleshooting, “Injector Solenoid Circuit Tes t” .

J2/P2 ECM connector and the J300/P300

h cylinder in order to isolate the misfiring

t on the active cylinders that are remaining

Note: Atmospheric pressure is not a default parameter on th

e status screen.

Air Inlet and Exhaust System

Check the air inlet and exhaust systems for restrictions and for leaks. Refer to Systems Operation/Te Exhaust System”. Look for an indication of the warning lamp or restriction indicators that are tripped if th These indicators are associated with plugged filters. Replace the plugged air filters or clean the plugged air filters a Operation and Maintenance Manual. Repair any leaks that are found in the system.

sting and Adjusting, “Air Inlet and

e filters are equipped with these devices.

ccording to the guidelines in the engine’s

i02281043

Mechanical Noise (Knock) in Engine

SMCS Code: 1000-035

Probable Causes

Driven equipment

•

Cylinder head and related components

•

Gear train

•

Fuel Supply

Check for a problem with the fuel supply and verify the fuel pressure. Verify that the fuel pressure sensor P209/J20 to Systems Operation/Testing and Adjusting, “Fuel System”.

9 is installed. For further information, refer

Boost Pressure Sensor (Intake Manifold Air), Rated Fuel Position and/or FR C Fuel Positio

1. With the engine at full load, monitor “Fuel Position”

2. Verify that there are no active diagnostic codes

3. Monitor air inlet manifold pressure and

and “Rat “Fuel Position” does not equal “Rated Fuel Limit”, then check air inlet manifold pressure.

that are associated with the boost pressure sensor or with

atmosp status screen.

ed Fuel Limit” on the status screen. If

the atmospheric pressure sensor.

heric pressure for normal operation on the

Crankshaft and related components

•

Piston

•

Recommended Repairs

Driven Equipment

Inspect the alignment and the balance of the driven equipment. Inspect the coupling. If necessary, disconnect the driven equipment and test the engine.

Cylinder Head and Related Components

Inspect the components of the valve train for good condition. Check for signs of damage and/or wear to the valves, cylinder head gasket, etc. Inspect the condition of the camshafts. If a camshaft is replaced, new valve lifters must be installed.

Gear Train

Inspect the condition of the gear train.

Page 49

RENR5042-02 49

Troubleshooting Section

Inspect the engine oil filters for nonferrous material. Flaking of nonf gear train bearings.

errous material could indicate worn

Crankshaft

Inspect the crankshaft and the related components. Inspect the co surfaces on the crankshaft. Make sure that the bearings are in the correct position.

Look for worn thrust plates and wear on the crankshaft.

Check the counterweight bolts.

nnecting rod bearings and the bearing

Piston

Make sure that the piston pin is correctly installed.

Inspect the condition of the pistons according to Guidelines for Reusable Parts and Salvage Operations

i02257027

Noise Comi ng from Cy linder

SMCS Code: 1000-035

Probable Causes

Diagnostic

•

Fuel quality

•

Unit injectors

•

Valve lash

•

codes

Unit Injectors

1. Check for correct installation of the J1/P1

and J2/P2 Electronic Control Module (ECM) connectors an connectors. Refer to Troubleshooting, “Electrical Connectors - Inspect”.

2. Perform the “Injector Solenoid Test” on Cat ET in

order to determine if all of the injector solenoids are being ene

3. Perform the “Cylinder Cutout Test” on Cat ET

in order to id misfiring. Refer to Troubleshooting, “Injector Solenoid Circuit - Test” for additional information.

d the J300/P300 unit injector

rgized by the ECM.

entify any injectors that might be

Valve Lash

Refer to Trou

bleshooting, “Excessive Valve Lash”.

i02290312

Poor Acceleration or Response

SMCS Code: 1000-035

Probable Causes

Engine “Derated”

•

Cold mode operation

•

Flash file

•

Throttle position sensor

•

Electrical connectors

•

Unit injectors

•

Recommende

d Actions

Diagnostic Codes

Check for active diagnostic codes on the Caterpillar Electronic Technician (ET). Troubleshoot any active codes befo

re continuing with this procedure.

Fuel Quality

Refer to Operation and Maintenance Manual for information on improving the characteristics of the fuel durin

g cold weather operation.

Fuel Position, Rated Fuel Limit, and FRC Fuel

•

Position

Air inlet and exhaust system

•

Fuel supply

•

Recommended Actions

Engine “Derated”

The engine may be derated due to dirty air filters or other factors. Use the Caterpillar Electronic Technician (ET) in order to check for engine derates.

Page 50

50 RENR5042-02 Troubleshooting Section

Cold Mode Operation

Monitor the status screen on Cat ET in order to verify that the engine has exited cold mode. Observe the reading for co to Troubleshooting, “System Overview” for additional information.

olant temperature on the Cat ET. Refer

Flash File

Verify that th

e correct flash file is installed.

Throttle Position Sensor

Monitor “Throttle Status” on Cat ET. Verify that the throttle position is stable and that the engine is able to reach high “Throttle Position Sensor Circuit - Test” for the proper troubleshooting procedure.

idle rpm. Refer to Troubleshooting,

Electrical Connectors

Check for co connectors for the Electronic Control Module (ECM). Check for correct installation of the JH300/P300 unit inject “Electrical Connectors - Inspect”.

Unit Inject

1. Use Cat ET to determine if there are any active

diagnostic

2. Perform the injector solenoid test on Cat ET in order to de are being energized by the ECM. Refer to Troubleshooting, “Injector Solenoid Circuit - Test” for the pro

rrect installation of the J1/P1 and J2/P2

or connectors. Refer to Troubleshooting,

ors

codes for the unit injectors.

termine if all of the injector solenoids

per procedure.

3. Monitor the “Boost Pressure” and “Atmospheric Pressure” for n is not running, “Boost Pressure” should be 0 kPa (0 psi).

ormal operation. When the engine

Air Inlet and Exhaust System

1. Check for an ai

plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.

2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/T Exhaust System”.

r filter restriction indicator. Clean

esting and Adjusting, “Air Inlet and

Fuel Supply

1. Check the fuel lines for the following problems:

restriction problems are found with the fuel lines, repair the lines and/or replace the lines.

2. Check the fuel tank for foreign objects which may block the fuel supply.

3. Check for air in the low pressure fuel supply system if any of the following procedures have been perfo

Replacement of the fuel filters

•

Service o n the low pressure fuel supply circuit

•

Replacemen

•

Note: A sight glass in the low pressure supply line is helpful in and Adjusting for more information.

s, collapsed lines, and pinched lines. If

rmed:

t of unit injectors

diagnosing air in the fuel. Refer to Testing

3. Perform the cylinder cutout test on Cat ET in order to identi Refer to Troubleshooting, “Injector Solenoid Circuit - Test” for the proper procedure.

fy any injectors that might be misfiring.

Fuel Position, Rated Fuel Limit, and FRC Fuel Position

1. Monitor the status of “Fuel Position” and “Rated

Fuel Limit” while the engine is operating under full load. If and “Fuel Position” is less than “FRC Fuel Limit”, the electronics are operating correctly. Otherwise, proceed

2. Verify that there are no active diagnostic codes for the boos

“Fuel Position” equals “Rated Fuel Limit”

to the next Step.

t pressure sensor.

NOTICE Do not cran 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

4. Purge air from the low pressure fuel supply circuit.

Refer to Operation and Maintenance Manual, “Fuel Syst

5. Cold weather adversely affects the characteristics

of the fue Maintenance Manual for information on improving the characteristics of the fuel during cold weather operatio

k the engine continuously for more than

em - Prime” for the correct procedure.

l. Refer to the Operation and

Page 51

RENR5042-02 51

Troubleshooting Section

6. Check the fuel pressure after the fuel filter while theengineisbe Adjusting for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel press items: fuel transfer pump, fuel transfer pump coupling, and fuel pressure regulating valve. Refer to Systems Op more information.

ing cranked. Refer to Testing and

ure is still low, check the following

eration/Testing and Adjusting for

i01405939

Valve Rotator or Spring Lock Is Free

SMCS Code: 1109-035

Probable Causes

Cracked valv

•

Broken spring locks

•

Broken valve spring(s)

•

Broken valv

•

Recommende

1. Determinethecauseofanengineoverspeedthat

would crack

2. Inspect the following components for damage:

Valve rotators

•

Spring lock

•

Valve springs

•

Valves

•

Note: Ensur piston. If the valve has contacted the piston, check the exhaust system for debris.

e rotator

d Actions

the valve rotator. Repair the condition.

e that the valve has not contacted the

3. Replace any damaged components.

Page 52

52 RENR5042-02 Troubleshooting Section

Troubleshooti

ng with a

Diagnostic Code

i02085761

Flash Codes

SMCS Code: 1900

Flash codes are a simple way to alert the operator that a problem exists with the engine’s control system or with the engine’s operation. Each flash code is a two digit number. The diagnostic lamp flashes in order to identify the flash code.

EXAMPLE

Note: Flash Code 27 would flash on the diagnostic

lamp in the following manner:

Two short flashes

•

Hesitation

•

Seven short flashes

•

Refer to Troubleshooting, “Diagnostic Code Cross Reference” for codes and a description of each code. There is a troubleshooting procedure for every diagnostic code. Refer to Troub Diagnostic Code”.

Whenadiagno Control Module (ECM) transmits information about the code over the J1939 data link. Some J1939 devices may d will be displayed with a SPN-FMI code. Refer to Troubleshooting, “Diagnostic Code Cross Reference” for a crossdiagnostic codes.

Do not confu Event codes alert the operator that an abnormal operating condition such as low oil pressure or high coolant tem Troubleshooting, “Troubleshooting with an Event Code” for additional information on event codes.

the complete list of the diagnostic

leshooting, “Troubleshooting With A

stic code is activated, the Electronic

isplay the code. However, the code

reference between SPN-FMI codes and

se diagnostic codes with event codes.

perature has been detected. Refer to

For the descriptions of the flash codes, refer to Troubleshooting, “Diagnostic Code Cross Reference”.

i02286316

Diagnostic Codes

SMCS Code:

Diagnosti

Diagnostic codes alert the operator that a problem in the electr codes also indicate the nature of the problem to the service technician. The Caterpillar Electronic Technicia designed to run on a personal computer. Diagnostic codes may be viewed on a personal computer that has Cat ET the component identifier (CID) and the failure mode identifier (FMI).

Component Identifier (CID) – The CID is a number with three or four digits. The CID indicates the compone the CID number 0001 identifies the fuel injector for the number one cylinder.

1900

cCodes

onic system has been detected. Diagnostic

n (ET) is a software program that is

software. Diagnostic codes consist of

nt that generated the code. For example,

Failure Mode Identifier (FMI) – The FMI is a two digit code that indicates the type of failure.

Illustration 10

Output voltage from a typical analog temperature sensor

g01117578

Page 53

RENR5042-02 53

Troubleshooting Section

Illustration 10 indicates the signal range for a typical analog sensor. the sensor’s output signal is below 0.2 VDC or above

4.8 VDC.

Diagnostic codes will be generated if

Active Diagnostic Codes

An active diagnostic code represents a problem with the electronic control system. Correct the problem

as soon as pos

When the ECM generates an active diagnostic code, the “Active A Status” on Cat ET) is activated in order to alert the operator. If the condition that generated the code is momentary list of active diagnostic codes. The diagnostic code becomes logged.

sible.

larm” indicator (“Engine Control Alarm

, the message disappears from the

Logged Diagnostic Codes

When the ECM generates a diagnostic code, the ECM logs the code in permanent memory. The ECM has an in will record the following information when a code is generated:

ternal diagnostic clock. Each ECM

i02172201

Diagnostic Code Cross Reference

SMCS Code: 1900

Problems with reported via these types of codes: flash codes, SPN/FMI codes, diagnostic codes, and event codes.

For information on flash codes, refer to Troubleshooting, “Flash Codes”.

For information on SPN/FMI codes, refer to Troubleshooting, “Diagnostic Codes”.

For information on diagnostic codes, refer to Troubleshooting, “Diagnostic Codes”.

For information on event codes, refer to Troubleshooting, “Event Codes”.

Use Table 14 as a cross reference between the various types of codes.

the electronic control system are

The hour of the first occurrence of the code

•

The hour of

•

The number of occurrences of the code

•

This information is a valuable indicator for troubleshooting intermittent problems.

A code is cleared from memory when one of the following conditions occur:

The service technician manually clears the code.

•

Thecodedo

•

A new code is logged and there are already ten

•

codes in me cleared.

Some diag Some diagnostic codes may log occurrences that did not result in complaints. The most likely cause of an inte or damaged wiring. The next likely cause is a component failure. The least likely cause is the failure of an ele logged repeatedly may indicate a problem that needs special investigation.

the last occurrence of the code

es not recur for 100 hours.

mory. In this case, the oldest code is

nostic codes may be easily triggered.

rmittent problem is a faulty connection

ctronic module. Diagnostic codes that are

Note: Always clear logged diagnostic codes after investigating and correcting the problem which generat

ed the code.

Page 54

54 RENR5042-02 Troubleshooting Section

Table 14

Cross Reference for Diagnostic Codes

Flash Code SPN

(1)

/FMI Code

Diagnostic Co

Event Code

1835-15 High Auxiliary Pressure Warning

1835-16 High Auxiliar

E443

1835-00

1836-15 High Auxiliary Temperature Warning

1836-16 High Auxiliary Temperature Derate

E445

1836-00

545-05

626-05

N/A

2417-05

545-06 Ether Start Relay short to ground

626-06

2417-06 Ether Injection Control Solenoid short to ground

1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt

1835-04 1835-04 Auxiliary Pressure Sensor short to ground

1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt

1836-04 1836-04 Auxiliary Temperature Sensor short to ground

111-02 111- 0 2 Engine Coolant Level Sensor Loss of Signal

174-03 174-03

174-04 174-04 Fuel Temperature short to ground

678-03 41-03 8 Volt DC Supply short to +batt

678-04 41-04

620-03

262-03 5 Volt Sensor DC Power Supply short to +batt

1079-03

620-04

262-04

1079-

100-03 100-03 Engine Oil Pressure open/short to +batt

100-04 100-04 Engine Oil Pressure short to ground24

100-10 100-10 Engine Oil Pressure abnormal rate of change

102-03 102-03 Boost Pressure Sensor short to +batt

102-04 102-04 Boost Pressure Sensor short to ground25

102-10 102-10 Boost Pressure Sensor abnormal rate of change

108-03 274-03 Atmospheric Pressure open/short to +batt

108-04 274-04 Atmospheric Pressure short to ground

110-03 110- 0 3 Engine Coolant Temperature open/short to +batt

110-04 110- 0 4 Engine Coolant Temperature short to ground

28 91-13 91-13 Throttle Position calibration required

32 91-08 91-08 Throttle Position signal abnormal

Description of Code

(2)

y Pressure Derate

High Auxiliary Pressure Shutdown

(2)

High Auxiliary Temperature Shutdown

Ether Start Relay open/short to +batt

Ether Injec

tion Control Solenoid open/short to +batt

Fuel Temperature open/short to +batt

8 Volt DC Supply s hort to ground

5 Volt Sensor DC Power Supply short to ground

(continued)

Page 55

RENR5042-02 55

Troubleshooting Section

(Table 14, cont

Cross Reference for Diagnostic Codes

Diagnostic Code

Flash Code SPN

(1)

/FMI Cod

Event Code

190-08 190-08

Engine Speed signal abnormal

723-08 342-08

190-15

E362

190-00

(2)

Secondary Engine Speed signal abnormal

Engine Overspeed Warning

Engine Overs

peed Shutdown

94-03 94-03 Fuel Pressure open/short to +batt

94-04 94-04 Fuel Pressure short to ground

105-03 172-03

Intake Manif

old Air Temp open/short to +batt

105-04 172-04 Intake Manifold Air Temp short to ground

42 637-13 261-13 Engine Timing calibration required

100-17

100-18 Low Engine Oil Pressure Derate46

100-01

E360

Low Engine O

(2)

Low Engine Oil Pressure Shutdown

il Pressure Warning

168-00 168-00 System Voltage high

168-01 168-01 System Voltage low51

168-02 168-02 System Voltage intermittent/erratic

56 630-02 268-02 Check Programmable Parameters

58 639-09 247-09 J1939 Data Link communications

110-15 High Engine Coolant Temperature Warning

110-16 High Engine Coolant Temperature Derate61

110-00

111-17 E059

111-18 E057

111-01 E058

E361

(2)

High Engine Coolant Temperature Shutdown

Low Engine Coolant Level Warning

Low Engine Coolant Level Derate

Low Engine Coolant Level Shutdown

111-17

111-18

111-01

E2143

(2)

Low Engine Coolant Level Warning

Low En

gine Coolant Level Derate

Low Engine Coolant Level Shutdown

63 94-15 E096 High Fuel Pressure Warning

1636-15 High Inlet Air Temperature Warning

1636-00

E539

(2)

High Inlet Air Te mperature Shutdown

174-15 High Fuel Temperature Warning

E363

(2)

High Fuel Temperature Shutdown

Injector Cylinder 1 open circuit

Injector Cylinder 1 short

Injector Cylinder #1 fault

174-16 High Fuel Temperature Derate65

174-00

651-05 001-05

651-06 001-06

651-11 001-11

Description of

Code

(continued)

Page 56

56 RENR5042-02 Troubleshooting Section

Cross Reference for Diagnostic Codes

(1)

/FMI Cod

652-05 002-05

652-06 002-06

652-11 002-11

653-05 003-05

653-06 003-06 Injector Cylinder 3 short73

653-11 003-11 Injector Cylinder #3 fault

654-05 004-05 Injector Cylinder 4 open circuit

654-06 004-06 Injector Cylinder 4 short74

654-11 004-11 Injector Cylinder #4 fault

655-05 005-05 Injector Cylinder 5 open circuit

655-06 005-06 Injector Cylinder 5 short

655-11 005-11

656-05 006-05

656-06 006-06

656-11 006-11

Diagnostic Code

Event Code

Description of

Injector Cylinder 2 open circuit

Injector Cylinder 2 short

Injector Cylinder #2 fault

Injector Cyl

Injector Cylinder #5 fault

Injector Cylinder 6 open circuit

Injector Cylinder 6 short

Injector Cylinder #6 fault

inder 3 open circuit

Code

(Table 14, cont

Flash Code SPN

(1)

Suspect Parameter Number

(2)

Caterpillar Electronic Technician (ET) w ill display the number 1, 2, or 3 after the event code in order to designate a warning, a derate, or a shutdown.

i02257686

CID 0001 FMI 05 Injector Cylinder 1 open circuit

SMCS Code: 1290-038

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit in the circuit for the injector.

System Response:

The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been logged.

Possible P erformance Effect:

Engine misfires

•

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

i02257712

CID 0001 FMI 06 Injector Cylinder 1 short

SMCS Code: 1290-038

Conditions Which Ge n erate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects a short circuit in the circuit for the injector.

System Response:

The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been logged.

Page 57

RENR5042-02 57

Troubleshooting Section

Possible P erformance Effect:

Engine misfires

•

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

i02214566

CID 0001 FMI 11

Injector

Cylinder #1 fault

SMCS Code: 12

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit or a s

If the cause of the diagnostic code is a problem in the common wire, of the shared common wire for the injectors.

System Respo

90-038

hort circuit in the circuit for the injector.

two cylinders will be affected because

nse:

i02257733

CID 0002 FMI 05 Injector Cylinder 2 open circuit

SMCS Code: 1290-038

Conditions Wh

The Electronic Control Module (ECM) is attempting to operate the circuit in the circuit for the injector.

System Respon

The ECM will log the diagnostic code. The ECM will continue to at code has been logged.

Possible Perf

Engine misfires

•

Low power

•

Troubleshoo

Perform the following diagnostic procedure: “Injector Solenoid Cir

Results:

OK – STOP.

•

ich Generate This Code:

injector. The ECM detects an open

se:

tempt to operate the injector after the

ormance Effect:

ting:

cuit - Test”

The ECM will log the diagnostic code. The ECM will continue t o code has been logged.

The injecto exists.

Possible Pe

Engine misfires

•

Low power

•

Perform the Solenoid Circuit - Test”

Results:

OK – STOP.

•

attempt to operate the injector after the

r may not operate while the condition

rformance Effect:

following diagnostic procedure: “Injector

i02257748

CID 0002 FMI 06 Injector Cylinder 2 short

SMCS Code: 1290-038

Conditions

The Electronic Control Module (ECM) is attempting to operate the in the circuit for the injector.

System Resp

The ECM will log the diagnostic code. The ECM will continue to code has been logged.

Possible P

Engine misfires

•

Low power

•

Which Generate This Code:

injector. The ECM detects a short circuit

onse:

attempt to operate the injector after the

erformance Effect:

Page 58

58 RENR5042-02 Troubleshooting Section

Troubleshooting:

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

i02214575

CID 0002 FMI 11

Injector

Cylinder #2 fault

SMCS Code: 129

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit or a s

If the cause of the diagnostic code is a problem in the common wire, of the shared common wire for the injectors.

0-038

hort circuit in the circuit for the injector.

two cylinders will be affected because

i02257759

CID 0003 FMI 05 Injector Cylinder 3 open circuit

SMCS Code: 1290-038

Conditions Wh

The Electronic Control Module (ECM) is attempting to operate the circuit in the circuit for the injector.

System Respon

The ECM will log the diagnostic code. The ECM will continue to at code has been logged.

Possible Perf

Engine misfires

•

Low power

•

Troubleshoo

ich Generate This Code:

injector. The ECM detects an open

se:

tempt to operate the injector after the

ormance Effect:

ting:

System Respo

The ECM will log the diagnostic code. The ECM will continue t o a code has been logged.

The injector exists.

Possible Pe

Engine misfires

•

Low power

•

Perform the Solenoid Circuit - Test”

Results:

OK – STOP.

•

nse:

ttempt to operate the injector after the

may not operate while the condition

rformance Effect:

following diagnostic procedure: “Injector

Perform the following diagnostic procedure: “Injector Solenoid Cir

Results:

OK – STOP.

•

cuit - Test”

i02257773

CID 0003 FMI 06 Injector Cylinder 3 short

SMCS Code: 1290-038

Conditions

The Electronic Control Module (ECM) is attempting to operate the in the circuit for the injector.

System Resp

The ECM will log the diagnostic code. The ECM will continue to code has been logged.

Which Generate This Code:

injector. The ECM detects a short circuit

onse:

attempt to operate the injector after the

Possible P

Engine misfires

•

Low power

•

erformance Effect:

Page 59

RENR5042-02 59

Troubleshooting Section

Troubleshooting:

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

i02214584

CID 0003 FMI 11

Injector

Cylinder #3 fault

SMCS Code: 129

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit or a s

If the cause of the diagnostic code is a problem in the common wire, of the shared common wire for the injectors.

0-038

hort circuit in the circuit for the injector.

two cylinders will be affected because

System Response:

The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been l

Possible Performance Effect:

Engine misfires

•

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

CID 0004 FMI 0

ogged.

i02257789

6Injector

Cylinder 4 short

System Respo

The ECM will log the diagnostic code. The ECM will continue t o a code has been logged.

The injector exists.

Possible Pe

Engine misfires

•

Low power

•

Perform the Solenoid Circuit - Test”

Results:

OK – STOP.

•

nse:

ttempt to operate the injector after the

may not operate while the condition

rformance Effect:

following diagnostic procedure: “Injector

i02257781

CID 0004 FMI 05 Injector Cylinder 4

SMCS Code: 1290-038

open circuit

SMCS Code: 12

Conditions Which Ge n erate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects a short circuit in the circui

System Response:

The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has bee

Possible Performance Effect:

Engine misfires

•

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

90-038

t for the injector.

n logged.

Conditions Which Generate This Code:

The Electr to operate the injector. The ECM detects an open circuit in the circuit for the injector.

onic Control Module (ECM) is attempting

Page 60

60 RENR5042-02 Troubleshooting Section

i02214587

CID 0004 FMI 11 Injector Cylinder #4 fault

SMCS Code: 1290-038

Conditions Wh

The Electronic Control Module (ECM) is attempting to operate the circuit or a short circuit in the circuit for the injector.

If the cause of common wire, two cylinders will be affected because of the shared common wire for the injectors.

System Response:

The ECM will lo continue to attempt to operate the injector after the code has been logged.

The injector may not operate while the condition exists.

Possible P erformance Effect:

Engine misfi

•

Low power

•

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

ich Generate This Code:

injector. The ECM detects an open

the diagnostic code is a problem in the

g the diagnostic code. The ECM will

res

Possible Performance Effect:

Engine misfires

•

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

i02257807

CID 0005 FMI 06

Injector

Cylinder 5 short

SMCS Code: 12

Conditions Which Ge n erate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects a short circuit in the circui

System Response:

The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been

90-038

t for the injector.

logged.

Results:

OK – STOP.

•

i02257799

CID 0005 FMI

05 Injector

Cylinder 5 open circuit

SMCS Code: 1

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit in

System Response:

The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has be

290-038

the circuit for the injector.

en logged.

Possible Performance Effect:

Engine misfires

•

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

Page 61

RENR5042-02 61

Troubleshooting Section

i02214590

CID 0005 FMI 11 Injector Cylinder #5 fault

SMCS Code: 1290-038

Conditions Wh

The Electronic Control Module (ECM) is attempting to operate the circuit or a short circuit in the circuit for the injector.

If the cause of common wire, two cylinders will be affected because of the shared common wire for the injectors.

System Response:

The ECM will lo continue to attempt to operate the injector after the code has been logged.

The injector may not operate while the condition exists.

Possible P erformance Effect:

Engine misfi

•

Low power

•

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

ich Generate This Code:

injector. The ECM detects an open

the diagnostic code is a problem in the

g the diagnostic code. The ECM will

res

Low power

•

Troubleshooting:

Perform the fol Solenoid Circuit - Test”

Results:

OK – STOP.

•

lowing diagnostic procedure: “Injector

i02257844

CID 0006 FMI 06 Injector Cylinder 6 sho

SMCS Code: 1290-038

Conditions Which Ge n erate This Code:

The Electron operate the injector. The ECM detects a short circuit in the circuit for the injector.

System Response:

The ECM will l continue to attempt to operate the injector after the code has been logged.

Possible Performance Effect:

Engine misfi

•

ic Control Module (ECM) is attempting to

og the diagnostic code. The ECM will

res

Results:

OK – STOP.

•

i02257822

CID 0006 FMI

05 Injector

Cylinder 6 open circuit

SMCS Code: 1

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit in

System Response:

The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has be

Possible P erformance Effect:

Engine misfires

•

290-038

the circuit for the injector.

en logged.

Low power

•

Troubleshooting:

Perform the f Solenoid Circuit - Test”

Results:

OK – STOP.

•

ollowing diagnostic procedure: “Injector

i02214594

CID 0006 FMI 11 Injector Cylinder #6

SMCS Code: 1290-038

Conditions Which Ge n erate This Code:

The Electro to operate the injector. The ECM detects an open circuit or a short circuit in the circuit for the injector.

If the cause of the diagnostic code is a problem in the common wire, two cylinders will be affected because of the shar

nic Control Module (ECM) is attempting

ed common wire for the injectors.

fault

Page 62

62 RENR5042-02 Troubleshooting Section

System Response:

The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been l

The injector may not operate while the condition exists.

Possible P erformance Effect:

Engine misfires

•

Low power

•

Perform the following diagnostic procedure: “Injector Solenoid Circ

Results:

OK – STOP.

•

ogged.

uit - Test”

i02257966

CID 0041 FMI 03 8 Volt DC Supply short to +batt

SMCS Code: 5574-038

i02257985

CID 0 041 FMI 04 8 Volt DC Supply short to ground

SMCS Code: 5574-038

Conditions Wh

The output voltage of the 8 volt supply falls below 7.5 VDC for at leas

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The diagnostic code may be viewed onadisplaymo Technician (ET). The ECM flags all digital sensors as invalid data and all digital sensors are set to the respective d

Possible Performance Effect:

Low power

•

Troubleshoo

Perform the following diagnostic procedure: “Digital Sensor Suppl

ich Generate This Code:

t two seconds.

dule or on Caterpillar Electronic

efault values.

ting:

yCircuit-Test”

Conditions W

The output voltage of the 8 volt supply exceeds 8.5 VDC for at lea

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The diagnostic code may be viewed on a display Technician (ET). The ECM flags all digital sensors as invalid data and all digital sensors are set to the respective

Possible P erformance Effect:

Low power

•

Troublesho

Perform the following diagnostic procedure: “Digital Sensor Sup

Results:

OK – STOP.

•

hich Generate This Code:

st two seconds.

module or on Caterpillar Electronic

default values.

oting:

ply Circuit - Test”

Results:

OK – STOP.

•

i02258022

CID 0091 FMI 08 Throttle Position signal abnormal

SMCS Code: 1913-038

Conditions

The frequency of the signal from the throttle that is connected t

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags the throttle position as invalid is used.

Possible P

Theenginespeedislimitedtolowidle.

Which Generate This Code:

o the primary throttle input is incorrect.

data and a default value of zero percent

erformance Effect:

Page 63

RENR5042-02 63

Troubleshooting Section

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

i02258069

CID 0091 FMI 13

Throttle

Position calibration required

SMCS Code: 191

Conditions Which Generate This Code:

The duty cycle of the signal from the throttle that is connected to the primary throttle input is incorrect.

System Response:

The Electron diagnostic code. The ECM flags the throttle position as invalid data and a default value of zero percent is used.

3-038

ic Control Module (ECM) will log the

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags fuel pressure as invalid data a is used.

Perform the fo Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

nd a default value of 600 kPa (88 psi)

llowing diagnostic procedure: “Engine

i02286373

CID 0094 FMI 04 Fuel Pressure short to g rou

SMCS Code: 1718-038

Conditions Which Ge n erate This Code:

The signal vo below 0.1 VDC for at least eight seconds.

System Respo

ltage from the fuel pressure sensor is

nse:

Possible P erformance Effect:

The engine speed is limited to low idle.

Troubleshoo

Perform the following diagnostic procedure: “Throttle Position Se

Results:

OK – STOP.

•

ting:

nsor - C alibrate”

i02286369

CID 0094 F M I 03 Fuel P ressure open/short to +batt

SMCS Code: 1718-038

Conditions

The signal voltage from the fuel pressure sensor is above4.95V

Which Generate This Code:

DC for eight seconds.

The Electronic Control Module (ECM) will log the diagnostic c invalid data and a default value of 600 kPa (88 psi) is used.

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

CID 0100 FMI

ode. The ECM flags fuel pressure as

i02281072

03 Engine Oil

Pressure open/short to +batt

SMCS Code: 1

Conditions Which Ge n erate This Code:

The signal voltage from the engine oil pressure sensor is above 4.95 VDC for at least eight seconds.

System Response:

924-038

The Electr diagnostic code. The ECM flags oil pressure as invalid data and a default value of 600 kPa (88 psi) is used.

Perform the following diagnostic procedure: “Engine Pressure S

onic Control Module (ECM) will log the

ensor Open or Short Circuit - Test”

Page 64

64 RENR5042-02 Troubleshooting Section

Results:

OK – STOP.

•

i02226250

CID 0100 FMI 04 Engine Oil Pressure short to gro un d

SMCS Code: 1924-038

Conditions Wh

The Electronic Control Module (ECM) detects all of the following

The signal voltage from the engine oil pressure

•

sensor is belo

Engine speed equals 0 rpm or barometric pressure

•

is greater th

Note: The trip point may be affected by the type of sensor that i

System Response:

ich Generate This Code:

conditions:

w 0.1 VDC for eight seconds.

an 47 kPa (6.8 psi).

s used for barometric pressure.

The engine oil pressure signal is within the

•

acceptable ran

The engine oil pressure signal remains abnormally

•

constant.

All of the above conditions occur simultaneously

•

foratleastth

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will f data. The value of the engine oil pressure is set to a default value.

Possible Performance Effect:

None

Troubleshooting:

Perform the following diagnostic procedure: “5 Volt Engine Pressure Sensor Supply Circuit - Test”

Results:

ge.

irty seconds.

lag the engine oil pressure as invalid

The ECM will log the diagnostic code. The ECM flags oil pressure as invalid data and a default value of 600kPa(87ps

Troubleshooting:

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

CID 0100 FMI

i) is used.

i02214839

10 Engine Oil Pressure Sen sor abnormal rate o f change

SMCS Code: 1924-038

Condition

This diagnostic code is designed to detect the loss of the 5 volt s

The Electronic Control Module (ECM) detects the following

The engine speed is greater than 600 rpm.

•

s Which Generate This Code:

upply at the sensor connector.

conditions:

OK – STOP.

•

i02281074

CID 0102 FMI 0

3Boost

Pressure Sensor short to +batt

SMCS Code: 1

Conditions Which Ge n erate This Code:

The signal voltage from the boost pressure sensor is above 4.8 VDC for one second.

System Response:

The Electro diagnostic code. The ECM will flag the boost pressure as invalid data and a default value is used for the boost pres

Possible Performance Effect:

Low power

Troublesh

Perform the following diagnostic procedure: “Engine Pressure S

917-038

nic Control Module (ECM) will log the

sure.

ooting:

ensor Open or Short Circuit - Test”

Page 65

RENR5042-02 65

Troubleshooting Section

Results:

OK – STOP.

•

i02281075

CID 0102 F MI 04 Boost Pressure Sensor short to ground

SMCS Code: 1917-038

Conditions Which Generate This Code:

The signal vol below 0.2 VDC for at least two seconds.

System Respon

The Electronic Control Module (ECM) will log the diagnostic c as invalid data and a default value is used for the boost pressure.

Possible P erformance Effect:

Low power

tage from the boost pressure sensor is

se:

ode. The ECM will flag the boost pressure

All of the above conditions occur simultaneously

•

for at least 30 s

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will fl The value of the boost pressure is set to a default value.

Possible Performance Effect:

Engine perfo

Troubleshooting:

Perform the following diagnostic procedure: “5 Volt Engine Pressure Sensor Supply Circuit - Test”

Results:

OK – STOP.

•

CID 0110 FMI 0

econds.

ag the boost pressure as invalid data.

rmance is adversely affected.

i02214851

3Engine

Coolant Temperatu re

Troubleshooting:

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

i02214842

CID 0102 F MI

10 Bo ost Pressure Sen sor abnormal rate o f change

SMCS Code: 1917-038

Conditions

This diagnostic code is designed to detect the loss of the 5 volt s

The Electronic Control Module (ECM) detects all of the follow

The engine speed is greater than 1000 rpm.

•

The signal from the boost pressure sensor is within

•

the acceptable range.

Which Generate This Code:

upply at the sensor connector.

ing conditions:

open/short to + bat t

SMCS Code: 1906-038

Conditions

The Electronic Control Module (ECM) detects the following c

The engine has been running for more than seven

•

minutes.

The signal voltage from the engine coolant

•

temperatur more than eight seconds.

System Resp

The ECM will log the diagnostic code if the engine has been ru check engine lamp will illuminate after a delay.

The ECM wil to a default value.

The engine diagnostic code is active.

The ECM wil has been active for more than eight seconds.

Which Generate This Code:

onditions:

e sensor is greater than 4.95 VDC for

onse:

nning for more than seven minutes. The

l set the value of the coolant temperature

will not go into cold mode while this

l activate the cooling fan after this code

The signal from the boost pressure sensor remains

•

abnormally constant.

Page 66

66 RENR5042-02 Troubleshooting Section

Possible P erformance Effect:

None

Troubleshooti

Perform the following diagnostic procedure: “Engine Temperature S

Results:

OK – STOP.

•

ng:

ensor Open or Short Circuit - Test”

i02214871

CID 0110 FMI 04 Engine Coolant Temperatu re short to ground

SMCS Code: 1906-038

Conditions Which Generate This Code:

The Electron following conditions:

The engine ha minutes.

ic Control Module (ECM) detects the

s been running for more than seven

i02290633

CID 0111 FMI 02 Engine Coolant Lev el Sensor Loss o f Signal

SMCS Code: 5574-038-CLT

Conditions Which Ge n erate This Code:

The signal fro

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The diagnostic code may be viewed on a display mo

Troubleshooting:

Perform the following diagnostic procedure: “Coolant Level Sensor Circuit - Test”

Results:

OK – STOP.

•

m the coolant level sensor is missing.

dule or on the electronic service tool.

i02281079

The signal vo temperature sensor is less than 0.2 VDC for more than eight seconds.

System Response:

The E CM will engine lamp will illuminate after a delay.

The ECM will to a default value.

The engine w diagnostic code is active.

The ECM will has been active for more than eight seconds.

Troublesho

Perform the following diagnostic procedure: “Engine Temperatu

Results:

OK – STOP.

•

ltage from the engine coolant

log the diagnostic code. The check

set the value of the coolant temperature

ill not go into cold mode while the

activate the cooling fan after this code

oting:

re Sensor Open or Short Circuit - Test”

CID 0168 FMI 0

0 System

Voltage High

SMCS Code: 14

Conditions Which Ge n erate This Code:

The Electronic Control Module (ECM) has been powered for at least three seconds. The ECM detects the followi

For 12 volt systems, the ECM reads battery voltage

•

that is abov

For 24 Volt systems, the ECM reads battery

•

voltage tha

Note: Excessive voltage to the ECM may damage the ECM.

System Response:

The ECM will log the diagnostic code.

Possible P

None

ng condition:

01-038

e16VDC.

t is above 32 VDC.

erformance Effect:

Page 67

RENR5042-02 67

Troubleshooting Section

Troubleshooting:

Perform the following diagnostic procedure: “Electrical Power Supply Circuit - Test”

Results:

OK – STOP.

•

i02281080

CID 0168 FMI 01

System

Voltage Low

SMCS Code: 140

Conditions Which Generate This Code:

The Electronic Control Module (ECM) has been powered for at least three seconds. The ECM detects the followin

For 12 volt systems, the ECM reads battery voltage

•

that is below

For 24 volt systems, the ECM reads battery voltage

•

that is below

System Response:

The ECM will log the diagnostic code.

g condition:

1-038

9VDC.

18 VDC.

The engine is running and battery voltage drops

•

below9VDCfora battery voltage recovers.

The engine is r

•

drops below 9 VDC three times in the last seven seconds.

System Response:

The ECM will lo

Possible Performance Effect:

Engine misfires

•

Engine shutdo

•

Troubleshooting:

Perform the following diagnostic procedure: “Electrical Power Supply Circuit - Test”

Results:

OK – STOP.

•

CID 0172 FMI 0

t least 0.06 seconds before the

unning and the battery voltage

g the diagnostic code.

i02258949

3Intake

Manifold Air Temp open/short

Possible Per

Engine misfires

•

Engine shutdown

•

Troubleshoo

Perform the following diagnostic procedure: “Electrica

Results:

OK – STOP.

•

formance Effect:

ting:

l Power Supply Circuit - Test”

i01942656

CID 0168 FMI 02 System Voltage intermittent/erratic

SMCS Code: 1401-038

Conditions

The Electronic Control Module (ECM) detects one of the followi

Which Generate This Code:

ng conditions:

to +batt

SMCS Code: 1921-038

Conditions

The engine coolant temperature is above −10 °C (14 °F). The air temperature sensor is greater than 4.95 VDC for more than eight seconds.

System Response:

The Electro diagnostic code. The ECM flags engine coolant temperature as invalid data and a default value of 40 °C (104 °

Possible Performance Effect:

None

Troublesh

Perform the following diagnostic procedure: “Engine Temperatu

Results:

Which Generate This Code:

signal voltage from the intake manifold

nic Control Module (ECM) will log the

F) is used.

ooting:

re Sensor Open or Short Circuit - Test”

OK – STOP.

•

Page 68

68 RENR5042-02 Troubleshooting Section

i02259267

CID 0172 FMI 04 Intake Manifold Air Temp short to ground

SMCS Code: 1921-038

Conditions Which Generate This Code:

The signal vol temperature sensor is less than 0.2 VDC for more than eight seconds.

System Response:

The Electroni diagnostic code. The ECM will flag the intake manifold air temperature as invalid data and a default value of 40 °C

Possible P erformance Effect:

None

Troubleshoo

Perform the following diagnostic procedure: “Engine Temperature

tage from the intake manifold air

c Control Module (ECM) will log the

(104 °F) is used.

ting:

Sensor Open or Short Circuit - Test”

Troubleshooting:

Perform the following diagnostic procedure: “Engine Temperature Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

i02259293

CID 0174 FMI 04

Fuel

Temperatur e short to grou nd

SMCS Code: 192

Conditions Which Ge n erate This Code:

The signal voltage from the fuel temperature sensor is below 0.2 VDC for eight seconds.

System Response:

The Electron diagnostic code. The ECM flags engine coolant temperature as invalid data and a default value of 50 °C (122 °F)

Possible Performance Effect:

2-038

ic Control Module (ECM) will log the

is used.

Results:

OK – STOP.

•

i02259280

CID 0174 FMI 03 Fuel Temperature open/short to +batt

SMCS Code: 1922-038

Conditions Which Generate This Code:

The engine c (14 °F). The signal voltage from the fuel temperature sensor is above 4.95 VDC for eight seconds.

System Response:

The Electr diagnostic code. The ECM flags engine coolant temperature as invalid data and a default value of 50 °C (122 °

Possible P erformance Effect:

Low power

•

oolant temperature is above −10 °C

onic Control Module (ECM) will log the

F) is used.

Low power

•

Troubleshoo

Perform the following diagnostic procedure: “Engine Temperatur

Results:

OK – STOP.

•

ting:

e Sensor Open or Short Circuit - Test”

i02259324

CID 0190 FMI 08 Engine Speed abnormal

SMCS Code: 1907-038

Conditions

The engine speed is greater than 120 rpm. The pattern for

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. If a valid signal is not received from the primar default to the secondary engine speed/timing sensor.

Which Generate This Code:

the timing ring is incorrect for five seconds.

y engine speed/timing sensor, the ECM will

Page 69

RENR5042-02 69

Troubleshooting Section

Possible P erformance Effect:

Engine misfires

•

Engine shutdow

•

Note: The engine will shut down only if the signals from the prima secondary engine speed/timing sensor are abnormal.

Troubleshoot

Perform the following diagnostic procedure: “Engine Speed/Timing

Results:

OK – STOP.

•

ry engine speed/timing sensor and the

ing:

Sensor Circuit - Test”

i02048968

CID 0247 FMI 09 J1939 Data Link co mmunications

SMCS Code: 1901-038

Conditions W

The Electronic Control Module (ECM) has detected a loss of commu

hich Generate This Code:

nications with the J1939 data link.

System Response:

The Electronic Control Module (ECM) will not log this code. The Caterpillar Electronic Technician (ET) will not be able to c

Possible Performance Effect:

Fuel injection is disabled. The engine will not start.

Troubleshoot

lear the code.

ing:

Check the Part Number of the Flash File

A. Turn the keyswitch to the ON position.

B. Verify that th

with the latest update that is available on Service Technician Workbench (STW), or on SIS Web.

Expected Result:

The correct f

Results:

OK – The correct flash file is installed in the ECM.

•

Repair: The e diagnostic code is cleared. Clearing this code requires factory passwords.

e part number for the flash file agrees

lash file is installed in the ECM.

ngine will not start until the 253-02

System Response:

The ECM will log the diagnostic code.

Possible Per

The engine may not operate properly. The equipment may not have e

Perform the following diagnostic procedure: “CAN Data Link Ci

Results:

OK – STOP.

•

formance Effect:

ngine speed control.

rcuit - Test”

i02265592

CID 0253 FMI 02 Perso nality Module mismatch

SMCS Code: 1902-038

Conditions

The flash file that is used for replacement is for a different application.

Which Generate This Code:

engine family or for a different engine

Acquire factory passwords. Clear the 253-02 diagnostic code. Return the engine to service.

STOP.

Not OK – The co

•

the ECM.

Repair: Fla flash file. Refer to Troubleshooting, “Flash Programming”. Verify that the problem is resolved.

STOP.

rrect flash file is not installed in

sh program the ECM with the correct

i02214901

CID 0261 FMI 13 Engine Timing Calibration required

SMCS Code: 1912-038

Conditions

Thetiminghasnotbeencalibratedsincethe Electroni calibration is incorrect.

System Res

Which Generate This Code:

c Control Module (ECM) was installed or the

ponse:

The ECM will log the diagnostic code.

Page 70

70 RENR5042-02 Troubleshooting Section

The ECM uses default timing.

Possible P erformance Effect:

Engine misfire

•

Low power

•

Reduced engine speed

•

White exhaust

•

Troubleshooting:

Perform the following diagnostic procedure: “Engine Speed/Timing Sensor - Calibrate”

Results:

OK – STOP.

•

CID 0262 FMI 03

smoke

i02259562

5 Volt Sensor

DC Power Supply short to

i02259643

CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground

SMCS Code: 5574-038

Conditions Which Ge n erate This Code:

The voltage le VDC for more than one second.

System Respon

The Electronic Control Module (ECM) will log the diagnostic co sensors to the respective default values.

Troubleshoo

Perform the following diagnostic procedure: “Analog Sensor Suppl

Results:

vel of the 5 volt supply is less than 4.84

se:

de. The ECM sets all of the pressure

ting:

yCircuit-Test”

+batt

SMCS Code: 5574-038

Conditions W

The voltage level of the 5 volt supply is greater than

5.16 VDC for m

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The ECM sets all of the pressure sensors to t

Troubleshooting:

Perform the following diagnostic procedure: “Analog Sensor Supply Circuit - Test”

Results:

OK – STOP.

•

hich Generate This Code:

ore than one second.

he respective default values.

OK – STOP.

•

i02261912

CID 0268 FMI 02 Check Programmable Parameters

SMCS Code: 1901-038

Conditions

One or more of the programmable parameters have not been pro

System Response:

The Electronic Control Module (ECM) will activate the diagnostic code.

Possible Performance Effect:

Engine perf unprogrammed parameters. The ECM may use a default torque map or the ECM may limit the engine to low idle

Which Generate This Code:

grammed.

ormance may be affected by the

Troubleshooting:

Program the system configuration parameters. Refer to Troubleshooting, “System Configuration Parameter

s” for additional information.

Page 71

RENR5042-02 71

Troubleshooting Section

Results:

OK – STOP.

•

i02071664

CID 0273 FMI 00 Turbo Outlet Pressure above normal

SMCS Code: 1917-038

Conditions Wh

The Electronic Control Module (ECM) detects all of the following

The outlet pressure of the turbocharger is greater

•

than 200 kPa (2

The engine speed is within 50 rpm of low idle for

•

five seconds

The ECM has been powered for at least three

•

seconds.

System Response:

ich Generate This Code:

conditions:

9psi).

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags atmospheric pressure as in 100 kPa (15 psi) is used.

Possible Perf

Low power

Troubleshooting:

Perform the fo Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

validdataandadefaultvalueof

ormance Effect:

llowing diagnostic procedure: “Engine

i02281092

CID 0274 FMI 04 Atmospheric Pressure sho

SMCS Code: 1923-038

rt to ground

The ECM will log the diagnostic code.

The ECM flags pressure as invalid data and a default value of 0 kPa (0 psi) is used.

Possible P erformance Effect:

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

CID 0274 FMI

turbocharger compressor outlet

i02281091

03 Atmospheric

Pressure open/short to +batt

SMCS Code: 1

923-038

Conditions Which Ge n erate This Code:

The signal vo sensor is below 0.2 VDC for at least eight seconds.

System Respo

The Electronic Control Module (ECM) will log the diagnos pressure as invalid data and a default value of 100 kPa (15 psi) is used.

Possible Performance Effect:

Low power

Troubleshooting:

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

ltage from the atmospheric pressure

nse:

tic code. The ECM flags atmospheric

Conditions Which Generate This Code:

The signal voltage from the atmospheric pressure sensor is above 4.8 VDC for at least eight seconds.

Page 72

72 RENR5042-02 Troubleshooting Section

i02286859

CID 0342 FMI 08 Secondary Engine Speed si gnal abnormal

SMCS Code: 1907-038

Conditions Wh

The Electronic Control Module (ECM) detects the following con

The engine speed is greater than 120 rpm.

•

The pattern for the timing ring is incorrect for five

•

seconds.

System Response:

The ECM will lo the secondary engine speed signal as invalid data and a default value of zero rpm is used.

Possible P erformance Effect:

Engine misfi

•

Engine shutdown

•

Note: The engine will shut down only if the primary engine speed/timing sensor and the secondary engine speed

ich Generate This Code:

ditions:

g the diagnostic code. The ECM flags

res

/timing sensor are abnormal.

Possible Performance Effect:

The engine may be difficult to start.

Troubleshooti

Perform the following diagnostic procedure: “Ether Injection Sys

Results:

OK – STOP.

•

ng:

tem - Test”

i02179467

CID 0545 F MI 06 Ether Start Relay short to ground

SMCS Code: 4493-038

Conditions W

The Electronic Control Module (ECM) is attempting to energize t circuit in the circuit for the ether relay.

System Respo

The ECM will log the diagnostic code.

Possible Performance Effect:

hich Generate This Code:

he ether relay. The ECM detects a short

nse:

Troubleshooting:

Perform the following diagnostic procedure: “Engine Speed/Timing Sensor Circuit - Test”

Results:

OK – STOP.

•

i02179461

CID 0545 FMI

05 Ether S tart

Relay op en/short to +batt

SMCS Code: 4

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to energize the ether relay. The ECM detects an open circuit in

System Response:

The ECM will log the diagnostic code.

493-038

the circuit for the ether relay.

The engine ma

Troubleshooting:

Perform the following diagnostic procedure: “Ether Injection System - Test”

Results:

OK – STOP.

•

CID 1835 FMI 0

y be difficult to start.

i02290640

3 Auxiliary Pressure Sensor open /sho rt to +batt

SMCS Code: 5574-038-PX

Conditions

The signal voltage from the auxiliary pressure sensor is greater t

Which Generate This Code:

han 4.8 VDC.

Page 73

RENR5042-02 73

Troubleshooting Section

System Response:

The Electronic Control Module (ECM) logs the diagnostic code. The value of the auxiliary pressure issettoadefa

Possible P erformance Effect:

None

Troubleshoot

Perform the following diagnostic procedure: “Engine Pressure Sens

Results:

OK – STOP.

•

ult value.

ing:

or Open or Short Circuit - Test”

i02290644

CID 1835 FMI 04 Auxiliary Pressure Sensor short to ground

SMCS Code: 5574-038-PX

i02290965

CID 1836 FMI 0 3 Auxiliary Temperature Sensor open/short to

SMCS Code: 5574-038-TA

Conditions Which Ge n erate This Code:

The output f ro greater than 4.8 VDC.

System Respon

The Electronic Control Module (ECM) will log the diagnostic co the default value.

Possible Per

None

Troubleshooting:

Perform the f Temperature Sensor Open or Short Circuit - Test”

m the auxiliary temperature sensor is

se:

de. The auxiliary temperature is set to

formance Effect:

ollowing diagnostic procedure: “Engine

+batt

Conditions Which Generate This Code:

The signal vo is less than 0.2 VDC.

System Respo

The Electronic Control Module (ECM) logs the diagnostic is set to a default value.

Possible Pe

None

Troubleshooting:

Perform the Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

ltage from the auxiliary pressure sensor

nse:

code. The value of the auxiliary pressure

rformance Effect:

following diagnostic procedure: “Engine

Results:

OK – STOP.

•

i02290973

CID 1836 FMI 0 4 Auxiliary Temperatur

e Sen so r short to

ground

SMCS Code: 5

Conditions Which Ge n erate This Code:

The signal voltage from the auxiliary temperature sensor is less than 0.5 VDC.

System Response:

The Electro the diagnostic code. The value of the auxiliary temperature is set to a default value.

Possible Performance Effect:

574-038-TA

nic Control Module (ECM) logs

None

•

Troubleshooting:

Perform the following diagnostic procedure: “Engine Temperature Sensor Open or Short Circuit - Test”

Page 74

74 RENR5042-02 Troubleshooting Section

Results:

OK – STOP.

•

i02178158

CID 2417 FMI 05 Ether Injection Control Solenoid current low

SMCS Code: 5479-038

Conditions Wh

The Electronic Control Module (ECM) is attempting to energize the e circuit in the circuit for the ether relay.

System Respon

The ECM will log the diagnostic code.

Possible P erformance Effect:

Theenginema

Troubleshooting:

ich Generate This Code:

ther relay. The ECM detects an open

se:

y be difficult to start.

Results:

OK – STOP.

•

Perform the following diagnostic procedure: “Ether Injection System - Test”

Results:

OK – STOP.

•

i02214983

CID 2417 FMI 0

6 Ether Injection

Control Solenoid current high

SMCS Code: 54

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to energize the ether relay. The ECM detects excessive current flo

System Response:

The ECM will log the diagnostic code.

Possible Pe

79-038

w in the circuit for the ether relay.

rformance Effect:

The engine may be difficult to start.

Troubleshooting:

Perform the Injection System - Test”

following diagnostic procedure: “Ether

Page 75

RENR5042-02 75

Troubleshooting Section

Troubleshooti

ng with an

Event Code

i02290980

Event C odes

SMCS Code: 190

Event codes alert the operator that an abnormal engine operat high coolant temperature has been detected. When the event code is generated, the event is active.

Active Event Codes

An active event code represents a problem with engine operation. Correct the problem as soon as

possible.

Active event codes are listed in ascending numerical order. The c

Illustration 11 is an example of the operating range of a temperatu troubleshoot temperature sensors.

ing condition such as low oil pressure or

ode with the lowest number is listed first.

re sensor. Do not use the Illustration to

Illustration 11

Example of the typical operating range of a temperature sensor

(1) This area represents the normal operating range of the

parameter. The normal output voltage of the s ensor is b etween

0.2 V DC and 4.2 VDC.

(2) In this area, the temperature above 107 °C (22 5 °F) is higher

than normal. The output voltage of the sensor will generate an event code. The sensor does not have an electronic problem.

(3) In these areas, the output voltage of the sensor is too high

or too low. T he voltage is outside of the normal range. The electronic problem will generate a diagnostic code. Refer to Troubleshooting, “Troubleshooting with a Diagnostic Code” for additional information on diagnostic codes.

Events are represented in two formats. In the first format, the “E” means that the code is an event code. The “XXX” represents a numeric identifier for the event code. This is followed by a description of the code. If a warning, a derate, or a shutdown is applicable, the numeric identifiers are different. Refer to the following example:

E004 Engine Overspeed Shutdown

•

In the second format, the “E” means that the code is an event code. The “XXX-X” represents a numeric identifier for the event code. The fourth “X” identifies the event as a warning, a derate, or a shutdown. This is followed by a description of the code. Refer to the following example:

g01138880

Page 76

76 RENR5042-02 Troubleshooting Section

E360-1 Low Oil Pressure Warning

•

E360-2 Low Oil Pressure Derate

•

E360-3 Low Oil P

•

The definition for a warning, a derate, and a shutdown are defined be

Warning – This condition represents a serious problem with e condition does not require a derate or a shutdown.

Derate – For th engine’s power in order to help prevent possible engine damage.

Shutdown – For this condition, the ECM shuts down theengineinordertohelppreventpossibleengine damage.

Logged Event

When the ECM generates an event code the ECM logs the code an internal diagnostic clock. The ECM will record the following information when an event code is generated:

ressure Shutdown

low:

ngine operation. However, this

is condition, the ECM reduces the

Codes

in permanent memory. The ECM has

Troubleshooti

For basic troubleshooting of the engine, perform the following step

1. Obtain the following information about the

complaint:

Theeventandthetimeoftheevent

•

Determine the conditions for the event. The

•

conditions will include the engine rpm and the load.

Determine if there are any systems that were

•

installed by t could cause the event.

Determine wh

•

occurred.

2. Verify that t

engine operation. Verify that the complaint is not due to error of the operator.

3. Narrow the probable cause. Consider the operator

information, the conditions of operation, and the history of t

s in order to diagnose a malfunction:

he engine.

he dealer or by the customer that

ether any additional events

he complaint is not due to normal

The hour of the first occurrence of the code

•

The hour of the last occurrence of the code

•

The number o

•

Logged events are listed in chronological order. The most recent

This information can be helpful for troubleshooting intermitt used to review the performance of the engine.

ent problems. Logged codes can also be

f occurrences of the code

event code is listed first.

Clearing Event Co des

Acodeiscl following conditions occur:

Thecodedo

•

A new code is logged and there are already ten

•

codes in me cleared.

The servic

•

Always clear logged event codes after investigating and corre code.

eared from memory when one of the

es not recur for 100 hours.

mory. In this case, the oldest code is

e technician manually clears the code.

cting the problem which generated the

4. Perform a visual inspection. Inspect the following

items:

Fuel supply

•

Oil level

•

Oil supply

•

Wiring

•

Connectors

•

Be sure to ch important for problems that are intermittent. Refer to Troubleshooting, “Electrical Connectors - Inspect”.

If these steps do not resolve the problem, identify the procedures in this manual that best describe the event. Che tests that are recommended.

eck the connectors. This is very

ck each probable cause according to the

Trip Points for the Monitoring System

The monitoring system determines the level of action that is ta in response to a condition that can damage the engine. When any of these conditions occur, the appropri

ken by the Electronic Control Module (ECM)

ate event code will trip.

Page 77

RENR5042-02 77

Troubleshooting Section

Table 15 contains the conditions that are monitored and the default condition has an associated parameter. The settings for each parameter can be viewed with the Caterpillar Electronic Te of the parameters may be adjustable with Cat ET .

trip points for each condition. Each

chnician (ET). The trip points for some

Page 78

78 RENR5042-02 Troubleshooting Section

Table 15

Trip Points for the Monitoring System

Parameter

Event

Code

Action

E057 Derate On 1to54 10

Low Coolant Level

E058

Shutdown Off

E059 Warning

High Fuel Pressure E096 Warning

Warning

Low Engine Oil Pressure

E360

Derate

Shutdown Off

Warning None 10

High Engine Coolant

Temperature

E361

Derate

Shutdown Off 1to54 10

Warning

Engine Overspeed E362

Shutdown

Warning 1to54 30

High Fue

l Temperature

E363

Derate

Shutdown Off

Warning On 1to54 4

(2)

E443

Derate 1to54 3High Auxiliary Pressure

Shutdown

Warning

High Auxiliary

Temperature

(2)

E445

Derate 1to54 4

Shutdown

Default

Seconds

Value

Range Default Range Default

1to54 10

Time Delay in

1to54 10

None 8 Maps are not programmable.

On 8

None

1to54 10

On None 1

1to54 10

Off

1to54 3

1to54 4

Off

1to54 4

Maps are not programmable.

85 °C (185 °F)

110°C(230°

86 °C (187 °F)

111 °C (232 °F)

87 °C (189 °F)

111 °C (232 °F)

C11/

C13

C15

C18

C11/

C13

C15

C18

70 °C (158 °F)

90 °C (194 °F)

71 °C (160 °F)

91 °C (196 °F)

0kPa(0psi)

3150 kPa (457 psi)

0°C(0

140 °C (284 °F)

Set Points

None

110 ° C

(230 °F)

111 °C

(232 °F)

1800-2600 2600

1800-2500 2500

1800-2800 2800

1800-2700 2700

90 °C (194 °F)

91 °C (196 °F)

1500 kPa

(218 psi)

105 °C

(221 °F)

°F)

106 °C

(223 °

107 °C

(224 °F)

(continued)

(1)

Page 79

RENR5042-02 79

Troubleshooting Section

(Table 15, cont

High Engine Air Inlet

(1)

The maps may b e different. The maps d epend on the model of the engine.

(2)

The engine must be equipped with the appropriate sensor.

Parameter

Temperature

Event

Code

E539

Trip Points for the Monitoring System

Action

Warning None 8

Derate

Default

Value

i02264589

E057 Low Engine Coolant Level Derate

SMCS Code: 1395-038-LO

Conditions Which Generate This Code:

The coolant level is below the coolant level sensor.

System Response:

The ECM will log the event.

Possible P erformance Effect:

Engine power is reduced.

Troubleshooting:

The coolant level is most likely low.

•

There may be a problem with the coolant level

•

sensor.

Time Delay in

Seconds

Range

1to54 8

Default

Range

None

Set Points

Default

75 °C (167 °F)

79 °C (174 °F)

Results:

OK – The coolant level is low.

•

Repair: Check the cooling system for leaks. Repair any problems that are found. Refill the cooling system to the proper level.

STOP.

Not OK – The coolant level is not low.

•

Repair: There may be a problem with the coolant level sensor. Refer to the diagnostic functional test Troubleshooting, “Coolant Level Sensor Circuit Test” in order to verify that the coolant level sensor is operating correctly.

Ensure that any repairs eliminate the problem.

STOP.

E058 Low Engine Coolant

i02274242

Check the Coolant Level

Pressurized System: Hot coolant can cause seri-

s burns. To open the cooling system filler cap,

ou stop the engine and wait until the cooling system components are cool. Loosen the cooling system

essure cap slowly in order to relieve the pres-

pr sure.

op the engine.

A. St

B. After allowing the engine to cool, check the coolant

vel. Refer to the Operation and Maintenance

le Manual for the proper procedure.

xpected Result:

The coolant level is low.

Level Shutdown

SMCS Code: 1395-038-LO

Conditions Which Ge n erate This Code:

The Electronic Control Module (ECM) detects a problem with the engine’s cooling system. Information on default settings and ranges for this event code can be found in Troubleshooting, “Event Codes”.

System Response:

The event code will be logged.

Possible Performance Effect:

E058 (Shutdown)

The engine will shut down.

Troubleshooting:

The coolant level is most likely low.

•

Page 80

80 RENR5042-02 Troubleshooting Section

There may be a problem with the coolant level

•

sensor.

Check the Coolant Level

Pressurized System: Hot coolant can cause serious burns. To open the cooling system f iller cap , stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

A. Stop the engine.

B. After allowing the engine to cool, check the coolant

level. Refer to the Operation and Maintenance Manual for the proper procedure.

Expected Result:

The coolant level is low.

Results:

OK – The coolant level is low.

•

System Response:

The event code will be logged.

Possible Perfo

E057 (Warning)

None

Troubleshoot

The coolant level is most likely low.

•

There may be a problem with the coolant level

•

sensor.

rmance Effect:

ing:

Check the Coolant Level

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling sy stem pressure cap slowly in order to relieve the pressure.

Repair: Check the cooling system for leaks. Repair

any problems that are found. Refill the cooling system to the proper level.

STOP.

Not OK – The coolant level is not low.

•

Ensure that any repairs eliminate the problem.

STOP.

i02274243

E059 Low Engine Coolant Level Warning

SMCS Code: 1395-038-LO

Conditions Which Generate This Code:

A. Stop the engine.

B. After allowing the engine to cool, check the coolant

level. Refer to the Operation and Maintenance Manual for the proper procedure.

Expected Result:

The coolant level is low.

Results:

OK – The coolant level is low.

•

Repair: Check the cooling system for leaks. Repair any problems that are found. Refill the cooling system to the proper level.

STOP.

Not OK – The coolant level is not low.

•

Ensure that any repairs eliminate the problem.

STOP.

Page 81

RENR5042-02 81

Troubleshooting Section

i02277367

E096 High Fuel Pressure

SMCS Code: 1250

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects a problem with the engine’s fuel pressure. Information on default set can be found in Troubleshooting, “Event Codes”.

System Respon

The event code will be logged.

Possible P erformance Effect:

E096 (Warning

None

Check the Fuel System

A. Verify that th

operating correctly. Check for damage or for dirt in the check valve.

B. Check the return line from the check valve to the

fuel tank for damage or collapse.

Results:

-038-HQ

tings and ranges for this event code

se:

)

e check valve in the fuel manifold is

E360-2 (Derate)

The engine power will be derated.

E360-3 (Shutdo

The engine will shut down.

Troubleshooting:

There may be a p system.

Check the Engi

A. Check the engine oil level. If the oil level is below

the oil pump’s have the ability to supply enough lubrication to the engine components. If the engine oil level is low, add engin engine oil level.

B. Check the fol

the engine oil pump:

a. Air leakage i

will also cause cavitation and loss of oil pressure. Check the supply side of the oil pump and make nec

b. Oil pump gears that have too much wear will

causearedu engine oil pump.

wn)

roblem with the engine’s lubrication

ne’s Lubrication System

supply tube, the oil pump will not

e oil in order to obtain the correct

lowing problems that may occur to

n the supply side of the oil pump

essary repairs.

ction in oil pressure. Repair the

OK – A problem

•

valve or in the return line to the fuel tank.

Repair: Repl

STOP.

was found in either the check

ace all suspect parts.

i02274316

E360 Low E ng ine Oil Pressure

SMCS Code: 1348-038-LP

Conditions W

The Electronic Control Module (ECM) detects a problem wit on default settings and ranges for this event can be found in Troubleshooting, “Event Codes”.

System Response:

The event co

Possible P erformance Effect:

E360-1 (Warning)

None

hich Generate This Code:

h the engine’s oil pressure. Information

de will be logged.

c. If the engin

pump, the scavenge pump may not be supplying oil to the main engine oil pump.

C. The inlet screen of the oil suction tube for the

engine oil pump can have a restriction. This restricti engine oil pressure. Check the inlet screen on the oil pickup tube and remove any material that may be rest pressure may also be the result of the oil pickup tube that is drawing in air. Check the joints of the oil picku seal.

D. If the eng

open position, a reduction in the oil pressure can be the result. This may be due to debris in the engine o stuck in the open position, remove each engine oil bypass valve and clean each bypass valve in order to each bypass valve bore.

E. Engine o

will cause low engine oil pressure. High engine oil level in the crankcase can be an indication of contam

on will cause cavitation and a loss of

ination.

e is equipped with a scavenge

ricting engine oil flow. Low engine oil

p tube for cracks or a damaged O-ring

ine oil bypass valves are held in the

il. If the engine oil bypass valves are

correct this problem. You must also clean

il that is contaminated with fuel or coolant

Page 82

82 RENR5042-02 Troubleshooting Section

F. Excessive clearance at engine bearings will

cause low engin components for excessive bearing clearance.

G. An oil line tha

will cause low engine oil pressure.

Expected Resu

An inspection of the engine’s lubrication system indicated a pr

Results:

OK – There is a problem in the engine’s lubrication

•

system.

Repair: Repair the problem. Ensure that the repair eliminates the problem.

STOP.

e oil pressure. Check the engine

t is open, broken, or disconnected

lt:

oblem.

i02274479

E361 High Engine Coolant Temperature

Check the Engine’s Cooling System

A. Verify that the cooling system is filled to the proper

level. If the coolant level is too low, air will get into thecoolingsy cause a reduction in coolant flow.

B. Check the radi

restriction to coolant flow.

a. Check for debr

of the radiator core. Debris between the fins of the radiator core restricts air flow through the radiator cor

b. Check internally for debris, dirt, or deposits on

the radiator restrict the flow of coolant through the radiator.

C. Check the mix

sure that the recommendations in the Operation and Maintenance Manual are followed.

D. Check the water temperature regulator. A water

temperature regulator that does not open, or a water tempe of the way can cause overheating.

stem. Air in the cooling system will

ator or the heat exchanger for a

is or damage between the fins

core. Debris, dirt, or deposits will

ture of antifreeze and water. Make

rature regulator that only opens part

SMCS Code: 1395-038-TA

Conditions W

The Electronic Control Module (ECM) detects a problem with on default settings and ranges for this event can be found in Troubleshooting, “Event Codes”.

System Response:

The event co

Possible P erformance Effect:

E361-1 (Warning)

None

E361-2 (Derate)

The engine power will be derated.

E361-3 (Shu

The engine will shut down.

Troubleshooting:

There may be system.

hich Generate This Code:

the engine’s cooling system. Information

de will be logged.

tdown)

a problem with the engine’s cooling

E. Check the wa

damaged impeller does not pump enough coolant. Remove the water pump and check for damage to the impe

F. If the cooling system for this application is

equipped w fan. A fan that is not turning at the correct speed can cause improper air speed across the radiator core. The radiator core can cause the coolant not to cool to the proper temperature differential.

G. Check for air in the cooling system. Air can enter

the cooling system in d ifferent ways. The most common c the incorrect filling of the cooling system and combustion gas leakage into the cooling system. Combust inside cracks, a damaged cylinder head, or a damaged cylinder head gasket.

H. Check the cooling system hoses and clamps.

Damaged hoses with leaks can normally be seen. Hoses t operation. The soft areas of the hose can become kinked or crushed during operation. These areas of the h become soft and/or get cracks after a period of time. The inside of a hose can deteriorate, and the

particles of the hose can restrict the coolant

loose flow.

ter pump. A water pump with a

ller.

ith a fan, check the operation of the

lack of proper air flow across the

auses of air in the cooling system are

ion gas can get into the system through

hat have no visual leaks can soften during

ose can restrict the coolant flow. Hoses

Page 83

RENR5042-02 83

Troubleshooting Section

I. If the cooling system for this application is

equipped with a line for the expansion tank. The shunt line must be submerged in the expansion tank. A restriction of the shunt line of the jacket water pump will cause a reduction in water pump efficiency. A reduction in water pump efficiency w

J. If the cooling system for this application

is equipped w aftercooler. A restriction of air flow through the air to air aftercooler can cause overheating. Check for debris o flow of air through the aftercooler.

K. Check for a r

restriction of the air that is coming into the engine can cause high cylinder temperatures. High cylinder te temperatures in the cooling system.

L. Check for a

A restriction of the air that is coming out of the engine can cause high cylinder temperatures.

M. Consider high ambient temperatures. When

ambient temperatures are too high for the rating of the coo temperature difference between the ambient air and coolant temperatures.

N. Consider high altitude operation. The cooling

capability of the cooling system is reduced at higher al is large enough to keep the coolant from boiling must be used.

titudes. A pressurized cooling system that

n expansion tank, check the shunt

from the expansion tank to the inlet

ill result in low coolant flow.

ith an aftercooler, check the

r deposits which would prevent the free

estriction in the air inlet system. A

mperatures cause higher than normal

restriction in the exhaust system.

ling system, there is not enough of a

E362 Engine Overspeed

SMCS Code: 7410

Conditions Which Ge n erate This Code:

The Electronic Control Module (ECM) detects an overspeed condition. Information on default settings and r Troubleshooting, “Event Codes”.

System Respon

The event code will be logged.

Possible Performance Effect:

E362-1 (Warni

None

E362-2 (Derate)

None

E362-3 (Shutdown)

The engine will be shut down.

Troubleshoot

The operator may be operating the machine incorrectly.

Talk to the Operator

-038; 7427-038

anges for this event can be found in

se:

ng)

ing:

i02291001

O. The engine may be running in the lug condition.

When the load that is applied to the engine is too larg When the engine is running in the lug condition, engine rpm does not increase with an increase of fuel. T coolant flow through the system.

Expect

A thorough inspection of the cooling system revealed aprobl

Results:

OK – There is a problem with the cooling system.

•

Repair

eliminates the problem.

STOP.

e, the engine will run in the lug condition.

his lower engine rpm causes a reduction in

ed Result:

em.

: Repair the problem. Ensure that the repair

Determine the events that caused the overspeed of the engine.

Results:

OK – STOP.

•

i02291100

E363 High Fu e

SMCS Code: 1250-038-TA

Conditions Which Ge n erate This Code:

The temperat point. Information on default settings and ranges for this event code can be found in Troubleshooting, “Event Code

System Response:

The event code is logged.

ure of the fuel has exceeded the trip

s”.

l Temperature

Page 84

84 RENR5042-02 Troubleshooting Section

Possible P erformance Effect:

E363-1 (Warning)

None

E363-2 (Derate)

The engine power is derated.

E363-3 (Shutd

Theengineisshutdown.

Troubleshooting:

Check the Fuel

Check the fuel system.

Expected Result:

A thorough ins a problem.

Results:

own)

System

pection of the fuel system revealed

The Electronic Control Module (ECM) will derate engine power.

443-3 (Shutdown)

The engine will shut down.

Troubleshoot

Use the Caterpillar Electronic Technician (ET) to view the parameter that the set points are valid for the application.

Determine the Make corrections in order to prevent the high pressure from recurring.

Results:

OK – STOP.

•

E445 High Aux

ing:

setting for auxiliary pressure. Verify

cause of the high pressure condition.

i02291151

iliary Temperature

OK – There is a problem with the fuel system.

•

Repair: Make the necessary repairs. Verify that the repair eliminates the problem.

STOP.

i02291109

E443 High Au xiliary Pressure

SMCS Code: 50

Conditions Which Generate This Code:

The pressure that is sensed by the auxiliary pressure sensor has exceeded the trip point. Information on default sett found in Troubleshooting, “Event Codes”.

System Respo

The event code will be logged.

Possible P erformance Effect:

443-1 (Warni

None

443-2 (Derate)

95-038-AX

ings and ranges for this event can be

nse:

ng)

SMCS Code: 50

Conditions Which Ge n erate This Code:

The pressure that is sensed by the auxiliary temperature sensor has exceeded the trip point. Information event can be found in Troubleshooting, “Event Codes”.

System Response:

The event co

Possible Performance Effect:

443-1 (Warning)

None

443-2 (Derate)

The Electronic Control Module (ECM) will derate engine power.

443-3 (Shutdown)

Theenginew

Troubleshooting:

Use the Caterpillar Electronic Technician (ET) to view the parameter setting for auxiliary temperature. Verify that the se

95-038-AX

on default settings and ranges for this

de will be logged.

ill shut down.

t points are valid for the application.

Page 85

RENR5042-02 85

Troubleshooting Section

Determine the cause of the high temperature condition. Mak high temperature from recurring.

Results:

OK – STOP.

•

e corrections in order to prevent the

i02286870

E539 High Intake Manifold Air Temperature

SMCS Code: 1050-038-TA

Conditions Which Generate This Code:

The Electroni a problem with the engine’s intake manifold air temperature. Information on default settings and ranges for th “Event Codes”.

System Respo

The event code will be logged.

Possible P erformance Effect:

E539-1 (Warn

None

E539-2 (Derate)

c Control Module (ECM) detects

is event can be found in Troubleshooting,

nse:

ing)

b. Check the quality of the coolant. Follow

the recommenda Maintenance Manual.

c. Check the radi

the inlet temperature of the coolant for the radiator. Compare the reading to the regulated temperature the outlet temperature of the coolant. A high temperature differential indicates an insufficient flow rate.

d. Check for air in the cooling system. Air can

enter the coo most common causes of air in the cooling system are the incorrect filling of the cooling system and c cooling system. Combustion gas can get into the system through inside cracks, a damaged cylinder he gasket.

e. Check the c

Damaged hoses with leaks can normally be seen. Hoses that have no visual leaks can soften dur hose can become kinked or crushed during operation. These areas of the hose can restrict the coola cracks after a period of time. The inside of a hose can deteriorate, and the loose particles of the hose c

f. If a sea water strainer is used in the application,

verify t

ing operation. The soft areas of the

nt flow. Hoses become soft and/or get

hat the sea water strainer is not plugged.

tions in the Operation and

ator for blockage. Check

. If the temperature is OK, check

ling system in different ways. The

ombustion gas leakage into the

ad, or a damaged cylinder head

ooling system hoses and clamps.

an restrict the coolant flow.

Theenginep

Troubleshooting:

Intake manifold air temperature can be high for the following reasons:

Engine’s cooling system

•

High ambien

•

High inlet air restriction and/or high altitude

•

Restriction in the exhaust system

•

Faulty inle

•

ower will be derated.

t air temperature

t air temperature sensor and/or circuit

Perform the following Inspections

A. Check the Engine’s C ooling System.

a. Verify that

proper level. If the coolant level is too low, air will get into the cooling system. Air in the cooling sys flow.

the cooling system is filled to the

tem will cause a reduction in coolant

g. Check the heat exchanger for a restriction to

the flow

h. Check the water pump. A water pump with

a damage coolant. Remove the water pump and check for damage to the impeller.

i. Check the water temperature regulator. A water

temperature regulator that does not open, or a water t part of the way can cause overheating.

j. If the c

equipped with an expansion tank, check the shunt line for the expansion tank. The shunt line m tank. A restriction of the shunt line from the expansion tank to the inlet of the jacket water pump w efficiency. A reduction in water pump efficiency will result in low coolant flow.

of water.

d impeller does not pump enough

emperature regulator that only opens

ooling system for this application is

ust be submerged in the expansion

ill cause a reduction in water pump

Page 86

86 RENR5042-02 Troubleshooting Section

k. If the cooling system for this application

is equipped wit aftercooler. A restriction of air flow through the air to air aftercooler can cause overheating. Check for debr prevent the free flow of air through the aftercooler.

m. Theenginema

When the load that is applied to the engine is too large, the engine will run in the lug condition. W lug condition, engine rpm does not increase with an increase of fuel. This lower engine rpm causes a red system.

B. Check for Hi

a. Determine if the ambient air temperature

is within t cooling system. When ambient temperatures are too high for the rating of the cooling system, th difference between the ambient air and coolant temperatures.

h an aftercooler, check the

is or deposits which would

y be running in the lug condition.

hen the engine is running in the

uction in coolant flow through the

gh Ambient Air Temperature

he design specifications for the

ere is not enough of a temperature

e. Consider high altitude operation. The cooling

capability of t higher altitudes. A pressurized cooling system that is large enough to keep the coolant from boiling must b settings for the engine are correct for the altitude.

D. Check the Engine’s Exhaust System.

Check for a re A restriction of the air that is coming out of the engine can cause high cylinder temperatures.

Expected Result:

A thorough in

Results:

Yes – A thorough inspection revealed a problem.

•

Repair: Repa eliminates the problem.

STOP.

he cooling system is reduced at

e used. Make sure that the

striction in the exhaust system.

spection revealed a problem.

ir the problem. Ensure that the repair

b. Determine the cause of the high air

temperature. Make corrections, when possible.

C. Check for High Inlet Air Restriction and/or

High Altitude

a. When inlet air pressure is low, the turbocharger

works harder in order to achieve the desired inlet man temperature.

b. Measure t

is operating under load. For specific data, refer to the Technical Marketing Information for the engine.

c. Check for plugged air filters. Check for

obstruc air that is coming into the engine can cause high cylinder temperatures. High cylinder tempera temperatures in the cooling system.

d. Replac

obstruction from the air inlet.

ifold pressure. This increases inlet air

he inlet air pressure while the engine

tions to the air inlet. A restriction of the

tures cause higher than normal

e the air filters and/or remove the

Page 87

RENR5042-02 87

Troubleshooting Section

Diagnostic Fun

ctional

Tests

i02289813

5 Volt Engine Pressure Senso r SupplyCircuit-Test

SMCS Code: 5574-038

System Opera

The Electronic Control Module (ECM) creates a regulated vo to terminal A of the harness connectors for these sensors:

Injection actuation pressure sensor

•

Boost pressu

•

Atmospheric pressure sensor

•

Fuel pressure sensor

•

tion Description:

ltage of 5.0 ± 0.2 VDC that is supplied

re sensor

Engine oil pr

•

Auxiliary pressure sensor (if equipped)

•

This procedure covers the following diagnostic codes:

262-03 5 Volt

•

+batt

262-04 5 Vol

•

ground

100-10 Engi

•

of change

102-10 Boos

•

change

A +5 V diagno short circuit to ground or a short circuit to another voltage source in the harness. The next likely cause is a proble a problem with the ECM.

essure sensor

Sensor DC Power Supply short to

t Sensor DC Power Supply short to

ne Oil Pressure Sensor abnormal rate

t Pressure Sensor abnormal rate of

stic code is probably caused by a

m with a sensor. The least likely cause is

Page 88

88 RENR5042-02 Troubleshooting Section

Illustration 12

Schematic for the 5 volt supply

Test Step 1. Inspec t the Electrical Connectors and the Wiring

A. Turn the keyswitch to the OFF position.

g01119880

Page 89

RENR5042-02 89

Troubleshooting Section

Illustration 13

Left side view

(1) Boost pressure sensor (2) Atmospheric pressure sensor (3) J2/P2 con nectors (4) J1/P1 con nectors (5) Engine oil pressure sensor

g01121143

Page 90

90 RENR5042-02 Troubleshooting Section

Illustration 14

The location of the fuel pressure sensor depends on the engine’s configuration.

(6) F uel pressure sensor

g01121144

B. Thoroughly inspect connectors (3) and (4).

Thoroughly inspect the connectors for each pressure sensor. Refer to Troubleshooting, “Electrical Connectors - Inspect”.

Illustration 15

P2 terminals tha t are associated with the 5 volt supply for the pressure sensors

(P2-17) Return (P2-54) Return (P2-72) +5 VDC (P2-80) +5 VDC

g01123205

Page 91

RENR5042-02 91

Troubleshooting Section

Illustration 16

P1 terminals that are ass ociated with the 5 volt supply for the pressure sensors

(P1-2) +5 VDC (P1-3) Return

g01123207

ion 17

Illustrat

J61/P61 terminals that are associated with the 5 volt s upply for the pressure sensors

(14) +5 VDC (15) Return

g01123208

Illustration 18

Connectors for the sensors

(A) Supply (B) Return (C) Signal

g01123211

C. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the pressure sensor supply.

Page 92

92 RENR5042-02 Troubleshooting Section

D. Check the allen head screw on each ECM

connector for t Troubleshooting, “Electrical Connectors - Inspect” for the correct torque values.

E. Check the allen head screw on the customer

connector for the proper torque. Refer to Troubleshoo for the correct torque value.

F. Check the har

and for pinch points from each sensor back to the ECM.

Expected Result:

All of t he con coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.

Results:

OK – The harn

•

OK. Proceed to Test Step 2.

Not OK – The c

•

OK.

Repair: Rep Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connector repair eliminates the problem.

he proper torque. Refer to

ting, “Electrical Connectors - Inspect”

ness and the wiring for abrasion

nectors, pins and sockets are completely

ess and connectors appear to be

onnectors and/or wiring are not

air the wiring and/or the connectors.

s are completely coupled. Verify that the

Results:

Active 03 code – An 03 diagnostic code is active.

•

ProceedtoTestStep3.

Active 04 code – An 04 diagnostic code is active.

•

ProceedtoTestStep5.

Active 10 code – A 10 diagnostic code is active.

•

ProceedtoTestStep4.

No active codes – None of the above codes are

•

active.

Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshoo Diagnostic Code”.

If the engine may be an intermittent problem in a harness that is causing the codes to be logged. Refer to Troublesho

STOP.

ting, “Troubleshooting Without a

is running properly at this time, there

oting, “Electrical Connectors - Inspect”.

Test Step 3. Check the Voltage on the +5 V Supply Wire

A. Turn the key

B. Disconnect the harness connectors for the

following s

switch to the OFF position.

ensors:

STOP.

Test Step 2. Check for Active Diagnostic Codes

A. Connect the Caterpillar Electronic Technician

(ET) to the service tool connector. Refer to Troubles

B. Turn the keyswitch to the ON position.

C. Observe the “Active Diagnostic” screen on Cat ET.

Wait at least 15 seconds so that any codes may become ac

•

Expected Result:

One of the

hooting, “Electronic Service Tools”.

tive. Look for these codes:

262-03

262-04

100-10

102-10

above codes is active.

Injection actuation pressure sensor J500/P500

•

Boost pressure sensor J200/P200

•

Atmospher

•

Fuel pressure sensor J209/P209

•

Engine oil pressure sensor J201/P201

•

Auxiliary

•

equipped)

C. Turn the ke

Note: Be sure to wiggle the harness during the

following intermittent condition.

D. Measure th

at each sensor connector on the engine harness.

Expected

Each voltage measurement is 5.0 ± 0.2 VDC.

ic pressure sensor J203/P203

pressure sensor J220/P220 (if

yswitch to the ON position.

measurements in order to reveal an

e voltage between terminals A and B

Result:

Page 93

RENR5042-02 93

Troubleshooting Section

Results:

OK – Each voltage measurement is 5.0 ± 0.2 VDC.

•

Repair: Connec Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to Troub

- Inspect”.

STOP.

Not OK – At least one voltage measurement is not

•

5.0 ± 0.2 VDC. or with the ECM. Proceed to Test Step 6.

Test Step 4. C V Supply Wire

A. Turn the keyswitch to the OFF position.

B. Disconnect the harness connectors for the

suspect sensor.

C. Turn the keyswitch to the ON position.

Note: Be sur

following measurement in order to reveal an intermittent condition.

D. Measure the voltage between terminals A and B

on the harness connector for the suspect sensor.

t all of the sensor connectors.

leshooting, “Electrical Connectors

There is a problem with the wiring

heck the Voltage on the +5

for the Suspect Sensor

e to wiggle the harness during the

Boost pressure sensor J200/P200

•

Atmospheric pressure sensor J203/P203

•

Fuel pressure s

•

Engine oil pressure sensor J201/P201

•

Auxiliary pressure sensor J220/P220 (if

•

equipped)

B. Wait for 15 seconds after you disconnect each

sensor. Look for the active 262-04 code to deactivate.

Expected Result:

The 262-04 diagnostic code deactivates when a particular sensor is disconnected.

Results:

OK – The 262-0

•

when a particular sensor is disconnected.

Repair: Conn returns, replace the sensor.

Connect all o problem is resolved.

STOP.

ensor J209/P209

4 diagnostic code deactivates

ect the suspect sensor. If the code

f the connectors. Verify that the

Expected Result:

The voltag

Results:

Yes – The voltage measurement is 5.0 ± 0.2

•

VDC. The 5 volt supply is present at the harness connector is an active 10 diagnostic code.

Repair: Re

Verify that the problem is resolved.

STOP.

No – The vol

•

VDC. The 5 volt supply is not present at the harness connector. There is a problem with the wiring or

e measurement is 5.0 ± 0.2 VDC.

for the suspect sensor. However, there

place the suspect sensor.

tage measurement is not 5.0 ± 0.2

with the ECM. Proceed to Test Step 6.

Te st Step 5. Disconnect the +5 V Pressure Sensors and C heck for Active Diagnostic Codes

A. Disconnect the following sensors one at a time:

on actuation pressure sensor J500/P500

Injecti

•

Not OK – The 262-04 diagnostic code remains

•

after all of t the sensors disconnected. Proceed to Test Step 6.

Test Step 6. for a Short t

he sensors are disconnected. Leave

Check the +5 V Supply Wire

o Engine Ground or a Short

Circuit

A. Turn the keyswitch to the OFF position.

B. Disconnect the J2/P2 ECM connector. Disconnect

the J1/P1 ECM connector.

C. Verify that all of the pressure sensors are

disconnected.

Note: Wiggle the harness during the following measurements in order to reveal an intermittent conditio

D. Measure the resistance between terminal P2-72

E. Measure t

F. Measure t

(+5 V Supp P2 connector.

and the engine ground.

(+5 V Supply) and all of the other terminals on the P2 connector.

ly) and all of the other terminals on the

he resistance between terminal P2-72

he resistance between terminal P2-80

Page 94

94 RENR5042-02 Troubleshooting Section

G. Measure the resistance between terminal P2-80

and the engine g

H. Measure the resistance between terminal P1-2

(+5 V Supply) a on the P1 connector.

a. Measure the re

and the engine ground.

Expected Resu

Each resistance measurement indicates an open circuit.

Results:

OK – Each resistance measurement indicates an

•

open circuit. Proceed to Test Step 7.

Not OK – At least one of the resistance

•

measurements does not indicate an open circuit. A +5 V supply wi problem with a connector.

Repair: Rep when possible. Replace parts, if necessary. Verify that the problem is resolved.

round.

nd all of the remaining terminals

sistance between terminal P1-2

lt:

re has a problem. There may be a

air the wire and/or the connector,

Repair: Repair the wire and/or the connector, when possible. that the problem is resolved.

STOP.

Replace parts, if necessary. Verify

Test Step 8. Check the +5 V Supply at the ECM

A. Remove terminal 72 (+5 V Supply) from the

P2 connector. Install a wire jumper with socket terminals on

B. Connect ECM connectors J2/P2.

C. Remove terminal 2 (+5 V Supply) from the P1

connector. Install a wire jumper with socket terminals on

D. Connect ECM connectors J1/P1.

E. Turn the keyswitch to the ON position.

F. Measure the

P1-2 and the engine ground.

G. Measure the

P2-2 and the engine ground.

both ends into P2-72.

both ends into P1-2.

voltage between the wire jumper in

STOP.

Test Step 7. the Sensor C

A. Install a wire jumper between terminals P2-72 (+5

V Supply) a

B. Install a wire jumper between terminals P1-2 (+5

V Supply) a

Note: Wiggle the harness during the following measureme short condition.

C. Measure th

B at the harness connector for each pressure sensor.

Expected Result:

Each resi

Results:

OK – Each measurement is less than ten Ohms.

•

Proceed to Test Step 8.

Check the +5 V Supply and

ommon for an Open Circuit

nd P2-3 (Sensor Common).

nd P1-3 (Sensor Common).

nts in order to reveal any intermittent

e resistance between terminals A and

stance measurement is less than ten Ohms.

H. Turn the key

I. Restore both wires to the original configuration.

Expected Result:

Both voltag

Results:

OK – Both voltage measurements are 5.0 ± 0.2

•

VDC.

Repair: Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to Tr

- Inspect”.

STOP.

Not OK – At least one voltage measurement is

•

not 5.0 ± 0.

Repair: Replace the ECM. Refer to Troublesh

STOP.

switch to the OFF position.

e measurements are 5.0 ± 0.2 VDC.

oubleshooting, “Electrical Connectors

2 VDC.

ooting, “Replacing the ECM”.

Not OK – At least one resistance measurement is

•

greater than ten Ohms. The +5 V supply wire or the retur may be a problem in a connector.

n wire has excessive resistance. There

Page 95

RENR5042-02 95

Troubleshooting Section

i02289818

Air Shuto ff System - Test

SMCS Code: 1078

System Operation Description:

The Electronic Control Module (ECM) has the ability to stop the engine by shutting off the inlet air supply in an emergenc relay which energizes the air shutoff solenoid. The solenoid trips the air shutoff valve.

There are two conditions which can cause the ECM to activate the air shutoff relay. The first condition occurs when t The relay will be energized until the ECM detects an engine speed of 0 rpm. The second condition occurs when a Theoverspeedverifyswitchisactivated.Whenthe engine speed reaches 75 percent of the programmed overspeed s

etpoint, the ECM will activate the air

shutoff relay. Again, this is used for testing purposes.

The air shut

off valve must be manually reset to the

OPEN position.

-038

y situation. The ECM activates a

he ECM detects an engine overspeed.

test of the air shutoff relay is made.

B. Verify that the air shutoff valves are set to the

Open position.

Illustration 19

Schematic for the air shutoff s ystem

Test Step 1. Inspec t the Electrical Connectors and the Wiring

A. Turn the keyswitch to the OFF position.

g00743757

Illustration 20

Left side view

(1) P61 customer connector (2) J1/P1 EC M c onnectors

g01121151

C. Thoroughly inspect connectors (1) and (2). Refer

to Troubleshooting, “Electrical Connectors Inspect”.

Page 96

96 RENR5042-02 Troubleshooting Section

Illustration 21

P1 terminals that are associated with the air shutoff system

(P1-11) Air shutoff solenoid (P1-54) O verspeed verify switch (P1-67) Solenoid common

g01102047

ion 22

Illustrat

J61/P61 terminals that are associated with the air shutoff system

(4) Air s hutoff solenoid (5) Solenoid common (40) Ov erspeed verify switch

D. Perform a 4

5 N (10 lb) pull test on each of the

g01123348

wires that are associated with the circuit for the air shutoff system.

E. Check the allen head screw on each ECM

connector for the proper torque. Refer to Troubles

hooting, “Electrical Connectors - Inspect”

for the correct torque values.

F. Check the

allen head screw on the customer connector for the proper torque. Refer to Troubleshooting, “Electrical Connectors - Inspect” for the co

rrect torque value.

G. Check the harness and the wiring for abrasion

and for pi

nch points from the air shutoff solenoid

to the ECM.

Expecte

dResult:

All connectors, pins, and sockets are completely coupled

and/or inserted, and the harness and wiring

are free of corrosion, of abrasion and of pinch points.

Page 97

RENR5042-02 97

Troubleshooting Section

Results:

OK – The connectors and wiring are OK. Proceed

•

to Test Step 2.

Not OK – The connectors and/or wiring are not

•

OK.

Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are p problem is resolved.

STOP.

roperly connected. Verify that the

Test Step 2. Test for Voltage from the Normally Open Contacts of the Air Shutoff Relay

A. Turn the keyswitch to the OFF position.

B. Remove the w

of the air shutoff relay that goes to the air shutoff solenoid.

C. Connect a test lamp between the normally open

contact of the air shutoff relay and engine ground.

ire from the normally open contacts

C. Connect a test lamp between the wire from the

normally open c engine ground.

D. Start the engi

E. Activate the overspeed verify switch.

F. Monitor the test lamp while you increase the

engine speed past 75 percent of the programmed overspeed set

Expected Result:

The test lamp illuminated when the engine speed increased past 75 percent of the programmed overspeed se

Results:

OK – The test lamp illuminated. The voltage is

•

present at the air shutoff solenoid.

Repair: Verify the continuity of the wire from the air shutoff solenoid to the negative battery before proceeding that the problem is resolved.

ontact of the air shutoff relay and

ne.

point.

tpoint.

. Replace the air shutoff solenoid. Verify

D. Start the engine.

E. Activate t

F. Monitor the test lamp while you increase the

engine spe overspeed setpoint.

G. Turn the ke

H. Disconnect the test lamp’s leads. Connect the

wire to the

Expected Result:

The test lamp illuminated when the engine speed increased past 75 percent of the programmed overspee

Results:

OK – The test lamp illuminated. The air shutoff

•

relay is operating correctly. Proceed to Test Step 3.

Not OK – The test lamp did not illuminate. Proceed

•

to Test Step 4.

he overspeed verify switch.

ed past 75 percent of the programmed

yswitchtotheOFFposition.

normally open contact.

d setpoint.

Test Step 3. Test for Voltage at the Air Shutoff Solenoid

STOP.

Not OK – The test lamp did not illuminate. System

•

voltage was There is a problem in the wiring between the air shutoff solenoid and the air shutoff relay. There maybeaprob

Repair: Repair the wiring and/or the connector. Replace pa is resolved.

STOP.

not present at the air shutoff solenoid.

lem with a connector.

rts, if necessary. Verify that the problem

Test Step 4. Test for Voltage at the Coil of the Air Shutoff Relay

A. Turn the keyswitch to the OFF position.

B. Disconnec

from the ECM to the air shutoff relay. Disconnect the wire at the coil of the air shutoff relay.

C. Connect the test lamp between the end of the wire

and engine ground.

D. Start the engine.

E. Activate

t the wire that carries the drive signal

the overspeed verify switch.

A. Turn the

B. Disconnect the wires that are connected to the

coil of t

keyswitch to the OFF position.

he air shutoff solenoid.

F. Monitor the test lamp while you increase the

engine sp overspeed setpoint.

eed past 75 percent of the programmed

Page 98

98 RENR5042-02 Troubleshooting Section

Expected Result:

The test lamp illuminated when the engine speed increased past 75 percent of the programmed overspeed set

Results:

OK – The test lamp illuminated. Verify the

•

continuity of the wire from the coil of the air shutoff relay proceeding. Proceed to Test Step 6.

Not OK – The te

•

voltage from the ECM was not present at the coil of the air shutoff relay. Proceed to Test Step 5.

point.

to the ECM connector P1-67 before

st lamp did not illuminate. The

Test Step 5. Short the Overspeed Verify Switch at the ECM

A. Turn the keys

B. Disconnect ECM connector P1.

C. Remove terminal P1-54 (overspeed verify switch).

D. Insert one e

for P1-54 (overspeed verify swtich). Connect the other end of the wire jumper to engine ground.

witchtotheOFFposition.

nd of a wire jumper into the socket

Repair: Verify the continuity of the wire for the overspeed veri Close the overspeed verify switch and measure the continuity from P1-54 to the negative battery. If the wire doe negative battery, repair the wire and/or replace the overspeed verify switch.

If the wire for the overspeed verify switch has continuity to the negative battery, there is a problem in th shutoff relay. Repair the circuit connectors or wiring and/or replace the circuit connectors or wiring. Verify that

STOP.

Not OK – The test lamp did not illuminate.

•

Repair: Per

1. Remove all jumpers and reconnect all terminals.

2. Temporarily install a new ECM. Refer to

Troubleshooting, “Replacing the ECM”.

3. Check the system for active diagnostic codes.

4. Perform thi

fy switch to the negative battery.

s not have continuity to the

ewiringbetweenP1-11andtheair

the problem is resolved.

form the following procedure:

sTestStepagain.

E. Remove terminal P1-11 (air shutoff solenoid).

F. Insert one e

for P1-11 (air shutoff solenoid).

G. Connect on

of the jumper wire in P1-11 (air shutoff solenoid).

H. Connect th

battery.

I. Start the e

J. Activate the overspeed verify switch.

K. Monitor the test lamp while you increase the

engine speed past 75 percent of the programmed overspeed

Expected Result:

The test lamp illuminated when the engine speed increased past 75 percent of the programmed overspee

Results:

OK – The test lamp illuminated.

•

nd of the wire jumper into the socket

e lead of the test lamp to the other end

e other lead of the test lamp to negative

ngine.

setpoint.

d setpoint.

5. If the problem is resolved with the test ECM, reconnect t problem returns. If the problem returns with the suspect ECM, replace the ECM.

6. Verify that the problem is resolved.

STOP.

he suspect ECM. Verify that the

Test Step 6. Test the Diode for Current Flow in One Direction

Illustration 23

Diode

A. Disconnect the wires from the air shutoff relay.

B. Remove the diode from the air shutoff relay.

C. Put the digital voltmeter (DVM) in “Diode Check”.

g00761537

Page 99

RENR5042-02 99

Troubleshooting Section

D. Refer to Illustration 23. Place the red lead of the

DVM on the diode lead of the DVM on the diode at location (B).

E. Measure the vo

Expected Result:

The voltage drop across the diode is less than one volt.

Results:

OK – The voltag

•

than one volt. Proceed to Test Step 7.

Not OK – The vol

•

greater than one volt.

Repair: Repla is resolved.

STOP.

at location (A). Place the black

ltage drop across the diode.

e drop across the diode is less

tage drop across the diode is

ce the diode. Verify that the problem

Test Step 7. Test the Diode for Current Flow in the Opposite Direction

A. Reverse the locations of the leads for the DVM.

B. Measure the v

oltage drop across the diode.

Expected Result:

The test lamp illuminates.

Results:

OK – The test lamp illuminated.

•

Repair: Replace the air shutoff relay. Verify that the problem is resolved.

STOP.

Not OK – The tes

•

to Test Step 9.

Test Step 9. Ch Keyswitch to

A. Turn the keyswitch to the OFF position.

B. Remove the wire from terminal R of the keyswitch.

C. Turn the keys

D. Measure the voltage between terminal B of the

keyswitch an

E. Measure the voltage between terminal R of the

keyswitch an

t lamp did not illuminate. Proceed

eck the Voltage from the

the Air Shutoff Relay

witch to the ON position.

d engine ground.

Expected Result:

The voltage drop across the diode is an OL.

Results:

OK – The voltage drop across the diode is an OL.

•

Proceed to T

Not OK – The voltage drop across the diode is

•

less than on

Repair: Replace the diode. Verify that the problem is resolved

STOP.

est Step 8.

evolt.

Test Step 8. Check the Voltage from the Keyswitch to the Normally Open Contacts of the Air Shutoff Relay

A. Turn the k

B. Disconnect the wire to the normally open contacts

of the air

C. Connectthetestlampbetweenthewireand

engine gr

D. Turn the keyswitch to the ON position.

eyswitch to the OFF position.

shutoff relay from the keyswitch.

ound.

F. Turn the keyswitch to the OFF position.

Expected Result:

Voltage is p the keyswitch.

Results:

OK – Voltage is present on terminal B and terminal

•

R at the keys

Repair: If voltage is present on terminal R, repair thewirebet relay. Verify that the breaker is not tripped. Return all wiring to the original configuration. Verify that the problem

STOP.

Not OK – Voltage is not present on terminal B at

•

the keyswitch.

Repair: If voltage is not present on terminal B, repair the wire between the +Battery and the keyswi tripped. Verify that the battery disconnect switch is operating correctly. Check the battery’s no-load v configuration. Verify that the problem is eliminated.

resent on terminal B and terminal R at

witch.

ween the keyswitch and the air shutoff

is eliminated.

tch. Verify that the breaker is not

oltage. Return all wiring to the original

STOP.

Page 100

100 RENR5042-02 Troubleshooting Section

Not OK – Voltage is not present on terminal R at

•

the keyswitch.

Repair: If voltage is present on terminal B of the keyswitch but the keyswitch. Return all wiring to the original configuration. Verify that the problem is eliminated.

STOP.

not present on terminal R, replace

i02289824

CAN Data Link Circuit - Test

SMCS Code: 190

System Operation Description:

The CAN data link is used to communicate information between the Electronic Control Module (ECM) and oth troubleshoot any suspect problems with the CAN data link.

This procedure covers the 247-09 diagnostic code. This procedure identifies the following problems:

Faulty connectors

•

Missing ter

•

Short circuits

•

Open circuits

•

Faulty J193

•

1-038

er modules. Use this procedure to

mination resistors

9display

Illustration 24

Schematic for the CAN data link

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